Greg,

switching resins strikes me as a bad idea if you ask me. The point being that polyester and epoxy are not compatible. Some say that you can use epoxy on polyester (for example on some fuses) but not vice versa - the polyester just won't cure over epoxy. For this same reason, the Dacron (polyester fabric) won't bond to the cured epoxy.

The idea is that you do your layup with assorted pieces of glass. If you need/want to use peel-ply on the bottom layers, by all means - I don't find it necessary. The Dacron is to obtain the smooth topmost layer. You don't need to flow epoxy just to add the Dacron if all else is cured - take advantage of the epoxy to bond the glass. When you've thoroughly wetted the 3/4 oz top layer(s), remove as much excess epoxy and add the peel-ply (Dacron) over top pulling it around the LE and TE. To avoid overflow I also use painters tape along the chord lines of where I want the glass to end. Before the epoxy is completely set, I cut along the inside edge of the tape making sure that I don't affect the wood. It will just leave a line as if you had scoured an actual piece of glass. As you lift the tape, you will find that it will leave you a clean line removing any excess cloth and peel-ply. Let the thing cure overnight and in the morning you can lift the peel-ply off.

It's not a problem to layup the glass cloth in multiple passes of epoxy and varying weights and sizes of cloth.

Hope that helps, David.