[lost2a6]

Brian, Some of the guys on this site have done their transom this way, Hammer being one of them. They would probably be able to give better information than myself. I would take one single sheet of plywood and glass on 3 layers of mat use something like polybond to go on the hull and the sides where the plywood stops. This Polly bond will be used as a bedding compound for the plywood and it can also be faired. Have friends put the Polly bond on the hull while you are putting the mat on the plywood, and then put the wood in the boat before everything has cured. The part of the wood that was glassed will go toward the bow of the boat. Once the wood is in the boat you want Polly bond to of squished out around the edges. Have the boat's transom 3 or 4 ft from a wall so once you put the wood in you can take several 2/4s and wedge in between the wall and the wood. This will insure that the wood bonds well to the inside of the boat, as you can see you must work quickly or the glass and/or Polly bond will of set up before everything is in place. Repeat this same procedure for the second sheet of plywood. When everything has cured, then start building up your outer skin to the wood. I would use 2 layers of mat, then 1 layer of woven roven, then 1 layer of mat, then 1 layer of woven roven, next I would put 4 layers of mat. This should get you pretty close to the original thickness of the original skin. Wouldn't hurt to use a little extra mat on the outside so that you have some material to grind down and make flat. Any thing that is glassed needs to have been sanded down smooth with a grinder first. The outer skin will need to be done in two steps.