Hi Marc, The aluminum tubing is only 10' in length, so there are already splices done with smaller tubing inserts sort of like tentpole connections. I've got a few extra pieces so I should be able to keep the length of the Sea Bee as planned. I also have enough of the HDPE to make the new, larger station forms for the Sea Bee. I'm not sure what the "extra holes" would be that you're talking about? As you say wood is definitely easier. I'm a woodworker by trade and would much rather work with wood. But cost-wise I've got the aluminum just sitting there (unless someone wants to buy a Sea Pup) and I'm wondering if it would be stronger for my intended purpose of getting trashed in the surf. It also seems like round tubes and HDPE forms would trap less water between it and the skin and result in less mold (Use will be exclusively fresh water). I guess the first question is does anyone use this boat for wave play and how is it? The 14' Petrel Play sounds like it would be better suited, but isn't ready for sale yet and would take significantly more time and money to build. In the meantime, I'm missing another great day of surf on Lake Ontario :-(