: The mold for the fiberglass kayak is built to a steve killings design and it
: was built by myself and friends strip planked and covered with 6oz cloth
: and faired with long broads. The mold is a male mold and if the frist boat
: turns out good we are going to make a female hull and deck mold and start
: useing gelcoat in the lay up. The frist hull was pulled off the mold
: yesterday. The lay up was two layers of 10 oz cloth and two layers of mat.
: the hull is stiff but still has give and weights 30 pounds which isn't bad
: because the store bought boat weight 60 pounds. the deck is going to be
: layed up of one layer of 10oz of cloth and two of mat which will be
: lighter then the hull. So hopefully the kayak will be around the some
: weight as the store bought boat. I will post some pictures soon

Since you are thinking of making a female mold from your plug (which is another name for the original male mold) why not use that first one you pulled off the plug? reinforce the thing by putting on "ribs" of fiberglass on the outside of the molded part, and add some feet to it so it can set flat. Then sand, buff and polish the inside until it is perfect. Take your time here and do it right. then coat with wax and mold release and try laying up your hulls.

The mat is a tremendous resin spone which adds little strength. For your deck you would be better off with two layers of cloth sandwiching a single layer of mat than to do the opposite. Your hull could do the same. For more strength put on a couple of layers of woven cloth, then the mat, then more woven cloth. In general, the more woven clith you use the stronger it will be, and the more mat you use the heavier it will be.

Just some thoughts. Good luck with your project.

PGJ