I think I'd go about the whole thing differently too. I'd probably stitch the whole thing together before applying any epoxy. Then just dab on some epoxy between the wires so the panels will hold their shape, then pull the two halves apart and lay in the fillets and glass cloth. That should make it a lot easier to match up each half without having to resort to spreader sticks.

I am almost positive but not totally convinced that there are errors in the offsets, the only way to be sure would be to build another one, keeping in mind the lessons learnt from the first. And I'm not going to do that cause there's too many other designs that are much easier (and faster) to build.

I'll do a couple more S&G's, then when I buy a house at the end of the year I'll get stuck into building a stripper.

Paul.

P.S. Here's a pic of my S&G 'G Boat'