Re: just rebuilt transom question
Well, W/o pictures we're kind of at a loss. Generally yes, transoms are 1 1/2 thick. Now if this a 10 ft jon boat with a 9.9 hp outboard, then 1 1/2 inches for the transom is a little much.
What was in the boat originally?
As for laminating the two layers of plywood, the statement about mat is correct because there are just enough flaws and imperfections in the wood that you'll never get the two pieces to fit together tightly. You need a filler in your epoxy glue. You can thicken the epoxy or use a fiberglass reinforcement. PS. Off the shelf mat is not compatible with Epoxy. It has a glue in it that holds the fibers together and the mat flat. This glue will only dissolve in Styrene, the solvent in Polyester resin.
There are specialty 'epoxy mats" look at the last item on this page:
http://www.uscomposites.com/mat.html
Fiberglass clothe and epoxy are no problem and you can use clothe instead of the mat to laminate the two layers of wood together.
I applaud your tests by pushing on the transom, but can you develop as much horse power as your OB does and what about the force your 250 LBS brother in law on the end of the ski tow rope puts on the transom?