RE: Wing Mold
I posted a note over in the pylon forum too, but you can also try Spyder Foam as a replacement for rohacell. I've used it on many occasions where it provided a better bonding surface to kevlar. Even though it has a vertical grain structure that you can use to your advantage, it still will dent like rohacell and easier. It is cheaper, but you have to hot wire it into thin sheets.
Michael