Life is a learning curve. Seems like I heard that somewhere. Well, epoxy use has been a learning curve too.

My initial attempts came up with glue-starved joints that didn't hold. I had to pop those apart (if they come apart that easy, it's obviously not right) and re-do them. Another learning item: don't let your retracting metal tape measure get epoxy on it and then retract. It actually did unspool again, but it pulled the paint – and thus the markings – off in places.

I have found that a much thicker mixture of epoxy, put on a good bit heavier than I was doing, seems to be doing pretty well. My only problem is that now I don't trust myself. I'm going to be paranoid about these glue joints for a while. This wasn't what I had expected in all my research and reading on this type of glue work, but...

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I'm using Cabosil for filler to thicken the epoxy. Works great. You can make most any consistency you decide you want. Cabosil (colloidal silica) is weird stuff. It looks kind of like snow, but with tiny, tiny flakes. And it weights nothing. Although the data sheet shows that it's not particularly dangerous, I would HIGHLY recommend some type of dust protection. It wants to blow everywhere and I can't believe it is great to breathe.

I have also learned through all this that some of these boards are not as flat as I thought. When you have an even very small cup in the board, you better get enough thickened epoxy in there to fill the gap. Epoxy doesn't stick if it doesn't touch the wood on the other side (duh).

I've corresponded with the designer to clarify a few assembly questions. Mark continues to impress me with quick turn around on answers (and they even make sense).

I've also gotten some of my assembly technique down a little more. Trying to glue up these frames with multiple pieces, all wanting to go their own way, can make for a little challenge catching them.

Milk jugs and the like full of water make nice weights to hold things down. Use plastic under joints so that you can get the frame loose of your garage floor (voice of experience). Make sure to put the temporary cross pieces at the top of the frames to hold things in place, and measure, measure, measure.

For background on the project, read my story: First Time Boat Builder Begins.