1,2) I made the mold myself using aluminum foil and aluminum tape to protect and cover areas that I would cover with one layer of fibreglass. This was used as the base and I later built up on it.
3) Carbon-fibre could work, but you have to be careful with the weave grain of the fibre as you lay it so that it will look good. Depending on your type of mold (negative/positive) you will also have to worry about getting the nice glossy finish after everything is completed. If this is your first time working with carbon-fibre, I suggest you practice using cheaper weaved fibreglass first.
4) Unfortunately I lost the only copies I had.

The total time in man-hours is probably around 100 or so, but that is only an estimate cause I do not really count these things. I just work on it when I have time. It was also done in stages with breaks in-between. Cost was under $1500 for everything (since labour was my own). The most expensive component was the HU cause I bought it new. Everything else was pre-used so I picked it up cheap.

A little technical though… -.-

1. could u provide leads to where u got the fibreglass mould done up?

2. What did u use to take the mould?

3. Would carbon-fibre work as well as the fibreglass?

4. Do u have any pictures of the diy in progress?

1.5years seems like quite a length of time spent, a rough gauge of the man hours involved would be useful.

Also, please advise the cost of the entire set up.

Thx!