Ken: I built my Peeler over the winter and got it in the water in June.
Try not to fixate on all the mistakes.... I sure made plenty. If the puzzle joints are not exactly flush, sand down a little, but, don't go through the plywood layer. I suggest practicing on a scrap piece so you know how much sanding you can get away with. Then, apply some pure epoxy (no filler) to smooth it over a little. By the time you put layers of epoxy and fiberglass over the hull, you won't notice anything.
SEATS: The first, second, third, fourth time fitting them, they not sit down on the bulkheads and tank sides without my inclination of forcing them to bow out the sides (not a good idea). The most important thing is to keep on planning off the side edges so they lay flat onto the bulkheads and tank sides. Otherwise, when you glue (peanut butter) the tops and lay down the seats, you might not get a good seal underneath....of course this is a problem because it won't be water-tight. Remember, once the seats are glued down, you can't go back underneath to fix it.
I think you had a question on whether you puzzle piece the entire seats together first before you install them? YES. But, as I mentioned, you'll go through this happy dance in dropping the assembled seats in, checking to see if there are any high spots on the bulkheads and/or tank sides (yes, there will be some), take it out, planning the seat side again, fitting again, planning some more, fitting again... and so on..... it really was a P.I.T.A.!
- Also, I suggest putting a layer of fiberglass on the seat tops BEFORE you install them. It'll take out the flex when stepping on them.
INSTALLING BULKHEADS: Try to get them exactly vertical even though the pre-drilled holes may not align correcting. Also, it'll drive you nuts, but the tips of the bulkheads may not be flush with the top of the board sides. Don't worry, you can saw the tips off later on AFTER you install the rails... no worries.
I'll check this forum in case you have any questions..... I made alot of mistakes but recovered and the boat turned out great!
SUE