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Old 08-05-2010
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plywood

Yes you can use plywood for the deck and sole BUT BE SURE IT IS MARINE GRADE PLYWOOD, not just "exterior grade" which may be sold as water proof by your local lumber yard. It isn't! It will rot in the course of a year or two. Marine grade is truly waterproof but it costs more, of course.

The difference between marine grade and pressure treated plywood - by Raymond Alexander Kukkee - Helium

To remove the sole just take a dremel tool with a cut off wheel and carefully work your way along the angle. Then use a belt sander to remove the remaining glass tape.

I wouldn't use noodles for flotation. Use a proper closed cell foam. You can get it in any custom size for a reasonable cost. One potential source is
Insulfoam in Kent, WA Phone 800-775-9424.
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