It's really not that hard Dave. It's time consuming and can get expensive. But not hard. I'm sure there's a cheap way of doing a one-off mold, but I just ain't wired like that. So when I make a mold, it's production level. And that gets expensive. I start out simple, but the A&P in me takes over and I just go nuts.

Get some polyurethane foam. Make a balsa backing and then just glue on the foam in a stack until it's bigger than the part. Then just sand it to rough shape. Apply resin and glass, and finish like normal. Paint it and wax the heck out of it. Then follow the instructions [link=http://www.cstsales.com/HTFiberglassMold.htm]here[/link] and it'll work out.

Here's a couple of quick snaps of my latest to give you an idea. If you have specific questions, ask in the composite forum here and guys like Mike James will hook you up.

-Mike