Hey, even the highest-end builder yards use filler and have to spend hours and hours fairing hulls smooth. It's just part of fiberglass boat building. Glass mat and resin set up different with each layup, even when using vacuum pumps in a controlled climate environment. Temperature, air pressure, humidity all impact on the day's work. The only difference in your case is there's no mold. Your boat could be the plug for a mold! Looks to me like you're experiencing most of the fiberglass boat building challenges the big yards come up against every day, Rick. Keep building 'er right and the results will speak for themselves!