Thanks David and Bob for your comments and weights. I've definitly have something to shoot for as far as weight is concerned.

Dave, The surface coat I used while making the molds is available from www.fibreglast.com and is a thick epoxy paste mixed 100 to 11(by weight) with its catalyst. You can also by the tints from there also. The surface coat is a better solution to using thickened resin although a lot of people will use thickened resin as a surface coat.

After applying the first coat of surface coat, I let it dry till its hard, but yet tacky (takes about 2 hrs) . I then apply the surface coat again, but work the first layer of glass cloth into it(I used 7.5oz cloth). After the glass cloth I followed up will 3 layers of fiberglass mat. This produced a mold of approximatley 1/4" thick.

I buy all my materials on line through: Fibreglast.com
Aerospace composites
The composite store (CST)

Also Aircraft Spruce Co. has a lot to offer in composite materials.

Hope this helps,

Todd