Used slow hardener and thin epoxy from US Composites (would give me about 45 minutes working time). Used (3) 1/2 birch plywood sheets, followed by a 3/4 sheet of oak. Probably major overkill but I am adding a engine bracket due to the transformation from cutout to full transom.

1) I mixed up the epoxy with chopped strand glass and coated the outer skin.

2) Placed the pre-coated plywood onto the outer skin. Followed with 1.5 oz mat.

3) Repeated number 2 for the rest of the plywood layers.

4) Screwed the entire assemply together from both the outer skin and from the oak (last sheet) in (so two directions) to remove voids. Probably 30 screws or so.

5) I then filled the edges with chopped strand/carbosil mixture.

6) Ontop of the last sheet (oak) I cover with 1.5oz mat / cloth /1.5 oz mat. And then tabbed to the hull with 1708 6" Biaxial tape. Like I said, probably overkill but what the heck. It doesn't add much weight to the boat.

MORE TO COME