: PVA is water based and would probably bond to, and soak into the masonite. I
: don't think wax would be enough or apply well over just masonite. Most
: molds are finished with tooling gel coat($$$) I think something epoxy
: based might work ok as substitute for this. My thought on mat was mostly
: price, If you tape the inside seams, and don't add the same thickness of
: glass to the rest you will end up with ridges or areas that were faired a
: lot. I suppose cloth will be thinner than mat, but cost more. If you use
: foam, it will definitly have be covered anyway. Another idea on fillers,
: you might mix up your own bondo,with a high percentage of microballoons to
: make a VERY easy sanding filler.

I agree w/ both david and bart:

the mold needs to be supported - by female forms.

The joints need to be faired. What about using dry wall compound? cheap as hell and sands well. You should use the drywall 'tape' that is ACTUALLY f/g so that the jts are slightly reinforced. Use part of a plastic bottle as the scraper to make a constant radius fillet.

the shiny surface needs to be sealed 1st to use a release. Probably any paint would work. And obviously paint the jts.

For the foot bumps, cut ovals in the forms, and say drape burlap sacking (or any cloth - towel?) into the holes wetted out w/ major glue. Let set up and cover w/ torn newspaper dipped into white glue like paper mache. Sand flush and it may work. Maybe tape a blown up balloon very slightly protruding into the hole to set the burlap shape first. Use the drywall compound on irregularities.

And when you'r done, you could actually stitch it together w/ some glass strands pulled from the 10oz cloth. Leave em in and then do the seams and they'll disappear.

-mick