Ok, my methodology is a little more drawn out than the casting method. Lets say its the "stuck cast/surfboard lamination method". I purchased 2 sheets of birch play ~ 1/8 thick. I cut the shape of the console using Limeydal's stats in consideration. I then put 2 layers of fiberglass mat in the inside using ~3/4 of a gallon of polyester resin and red pigment. Can you say mad VOC?
This is the stuck cast method since it was applied like a cast without the pva release agent (it ain't coming out). Next I used woven fiberglass for the exterior. I mixed resin and pigment to make a "searider orange" resin mix. My next procedure is the "surfboard lamination method". I predetermined the shape of the to be wrapped fiberglass using butcher paper to make for a clean fit. I then used the template to cut the glass for a clean 2 piece fit to the outer skin of the pod. To finish things off I will be gelcoating with a waxing agent tomorrow and then a nice light wetsanding to smooth things out.
This is of course not the preferred method of making a pod but it works. When finished the pod should weigh in at 20-24 lbs. It should be quite stout.
Any opinions suggestions would be appreciated.
Other things I've been doing to my newly acquired boat are a oem trim gauge, Smart tab trim tabs,fuel flow indicator, and a custom front bow seat. Next on my list is a bow spray dodger. This will be made of bright orange canvas and affixed to the bow and top center of the console. More pics to come as the projects complete.