We drove all the way to Springfield, MA, to buy fiberglass and resin. After talking to Joe, the fiber-man, we decided to go for polyester resin instead of epoxy. It is much cheaper, cures much faster, and is much stiffer than epoxy. Sounds exactly what we want/need. We also bought more expensive fiberglass cloth: a bi-directional weave with fiberglass mat stitched to the back that allows us to build up thickness much faster and to absorb the resin better.
We started what seemed (and later prooved to be true) a crazy task: assembling the six molds that would allow us to work in parallel.03-28-06
Since polyester smells extremely bad, we decided -in order not to loose our paint shop privileges- to do our tests with the new material outside. The quick tests done yesterday came out very well and look really promising!