http://www.hobiecat.com/support/images/ ... mplate.jpg
Be careful with the router! Get the hulls / foam as dry as possible. I would suggest to create a course surface (sand with some really course sandpaper) and start laminating. Use glass cloth - Probably tape style. Use a good quality epoxy (west system is good stuff but there are others as well) Do not think you could make it better, stronger or longer lasting with Kevlar or carbon.
Think about buying or building a set of beach wheels.
Patrick