I like Dan's technique for a nice clean fillet. I wonder why he does not need to precoat. That dry wood looks like it would suck the epoxy right out of the mix and hed get a dry bond and weak bond?
Dave it looks to me like he's already epoxy coated his ply and probably very lightly sanded it.
Hey now that I have your attention, on your Jumbo side windows: For the aft non moveable lexan did you route a rabbet in the ply for the lexan, and simply hold the lexan in place with silicone as Renn suggests in the book? No screws?
Looks like you bought channel for the sliding lexan window. Which channel did you buy (plastic or aluminum, brand).
How did you secure the channel in place.