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why dont you just fiberglass the cardboard??? n put hinges on the lid? looks good man
I havent done it yet, but from what I have been reading you should cover your mold with saran wrap or plastic. Make sure that it is tight with no wrinkles or spots sticking up. Then coat it in wax or something so that the mat wont stick to it. Then put your mat on, and coat it with resin. Criss-cross your first layer and second layer. This will provide some more rigidity.Keep us updated on the progress
Have you thought of mounting a radio and speakers in it??