> I work for an ornamental plastering contractor and such molds are well
> within our grasp. Well-supported, the mold would not need to be as thick as
> 5 times the thickness of the desired cast.

Yeah, I was thinking about that. The Adventurewagen top weighs what,
200-odd pounds? No way the molds for them weigh a half ton! The "5x
rule" must be for smaller, unreinforced fiberglass molds. Looking back
at the pics of the AW molds, they seem to have a significant wood
skeleton.

> the interior finish doesn't have to be an interior mold. One could simply
> make a liner mold that allowed for some insulating space between outer shell
> and inner shell.

Even easier, I bet, would be something as mundane as epoxied on
1/2"-3/4" furring strips of wood or aluminum acting as wall stud type
dealies. This would allow a space for insulation and even a little
wiring, with maybe thin masonite or PVC sheeting screwed on, covering
it. Though if it were me, I'd be so sick of it by the time I got the
outer shell done that I'd probably just glue up a few yards of gray
indoor/outdoor carpet and call it done. Heck, Westfalia did me one
better, using some sort of spray on flocking!

--
John Bange
'90 Vanagon - "Geldsauger"