Nick shows how to hand-cut stitch and glue plywood boat panels from scratch, an alternative to buying a pre-cut CNC kit. He covers scarfing shorter plywood pieces together using an 8:1 planed joint and thickened epoxy, then transfers full-size paper patterns onto the plywood using a pounce wheel and spray adhesive. After drilling stitch holes, he cuts the panels with a fine-toothed jigsaw blade and cleans the edges with a well-sharpened block plane.

Accurate measurement and thorough mixing are crucial for successful epoxy use. Nick discusses the pros and cons of dispensing pumps, calibrated cups, kitchen scales and professional benchtop pump systems for measuring epoxy prior to mixing.

A friend accidentally damaged the exterior fiberglass of a Petrel Sport kayak while paddling along the Bold Coast of Maine. I repaired the damage by sanding, staining, and applying multiple layers of fiberglass and varnish, resulting in a repair that is barely noticeable.