Hi Rob,
To make the plugs and moulds its a massive amount of man hours, to date on the single seater for 2 moulds, although very complex i have spent about 250 hours to date. Material costs aren't too bad though. For the personal satisfaction of making all your own build parts some people would find it worthwhile.
For the gel coat i wouldn't really worry about spray coat as brush on gel is probably better for the intricate moulds for the roadster.
All the Best....AndrewH
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