I'm not pretty seriously thinking about building a 9 1/2 foot sailing dinghy, stitch and glue. I think I can get the patterns for the panels printed out full sized. So, I thought I might glue them to door skins, cut them out, and router the shapes in the wood I actually build the boat with. That way, if I decide to build another, it's dead easy.
Then it occurred to me that this would create a much smoother edge than cutting it with a jig saw, and that might not be a good thing, because a rougher edge would presumably give the epoxy a better grip. Is this a real problem, or should I go the router route?
I'm also hoping to come up with the least unpleasant way to deal with sanding down the fillets. I don't fancy being covered with little glass daggers, and I sure don't want to breath them. For such a small boat, is wet sanding a viable option?
This is the boat I'm thinking of building. It would carry an El Toro rig, which I've already got.
I'm thinking of building it in 1/8 inch plywood, which would make it a bit fragile, but quite light. The plan is to have a boat I can carry down to the beach and toss the rig in and go sailing with little rigging time, and it needs to be narrow enough to fit in the back of my pickup truck and big enough to carry two people without much trouble.
I've only built one boat (well, except for a plywood boat I helped my dad build,) and I've not built stitch & glue before, so any advice would be helpful.