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I'm using a similar method but maybe slightly more accurate.
I have many areas that I've completely routed out that I now have to fill in. The initial cuts were routed out using 1/8" doorskin templates. To fill back in, I glued up strips on the workbench to slightly larger size than the hole. I then taped drafting tracing paper tightly over the holes in the yak, and then ran a pencil on the FLAT around the 'hole' profile therebye getting the exact shape outlined on the paper (you press the pencil on edge around the hole - you get a smudgy wide smear with a dark line exacly to the hole size).
Then remove the tracing paper, scissor cut close (1/2") to the shape, lightly spray glue, and slap it on the laid up filler piece. Then bandsaw to the line, then test and file, test and file, test and file, test and file . . . . . . .
-mick (call me testy)
This is an archived message from The Kayak Building Bulletin Board.