When does the desired lightness of the craft create strength limitations. I am sure the answer is rather complicated and dependent on a whole host of factors. I have just completed the forms for my son's Grebe. He is 90 lbs. I weigh 235 lbs. and will be building an Outer Island next. I would like to not limit where we can paddle our kayaks.

I would love to build as light as possible....especially the OI given its size. If I used three layers of 2 ounce cloth, would that be as strong as one six ounce layer of cloth. It appears that there would be a weight saving due to less epoxy used. Will the use of 3/16 strips for decreased weight be less structurally sound than the use of 1/4 strips given both have the same glass applications?

I have taken a look at some of the strip/glass strength ratios in the archives and on different sites. I am curious. For those of you who have had years of paddling experience with different layups.....have you run into problems when playing with strip width and glass layup in order to reduce weight.

The bottom line is...I want a safe and sound boat for my son and I....but light too...so....when does the reduction in strip or glass become detrimental to the structure of the kayak? I really appreciate your thoughts.
Bob