[jgmick]

I'm heading toward more of a 3-D shape. (Like a shoe box cover) Edges curved and corners rounded. I have banged out most of the details for a mold, now I have to figure out the materials.
Among other things I'm trying to decide on a gel coat layer or not. I'm not sure that gets me anything. I assume I will have to wet sand and fill the finished surface and fair it into the sheet metal side walls with body putty. The gel coat doesn't really get me much.
I like your idea of using a piece of glass and making a really thin layer that would be bendable. That's slick. May have a use for that.