: thanks all

: so what thickness of ply would be suggested in a light build?

: cheers

Just some thoughts in no particular order.

The CLC Pax20 reccomends 4mm for the bottom panels only and 3mm for sides and deck. I haven't built one of these so can't comment further.

I have a Ch17 with 4mm deck. Epoxy and varnish. I can see no reason whatsoever to add glass to the deck and I've been smashed around a bit in the surf.

I've recently designed an ocean racing ski (with lots of help) using KayakFoundary and one suggestion that I liked to keep weight down(from Bill H. I think) was to skin the deck ala' SOF.

No end pours as suggested previously.

Carbon and glass combing rather than ply combing. See OneOceanKayaks. this will be heaps lighter than ply method. A mate of mine used this method on a S&G with great success.

Cheers