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For short run stuff, or an intermediate mold I wouldn't form directly over more than a few times, I might use something like water putty or gypsum cement, with drywall tape reinforcement.


For something really durable, I'd probably go with a resin impression coat, and lay up some fiberglass of some sort under that.  Maybe just a healthy layer of Bondo-Glass.  (Which is not like regular Bondo.  It's not easy to sand, and it's much stronger, because it's filled with glass fibers instead of little microbubbles.)


If I still wanted to be able to sand and modify it easily, at the expense of making it somewhat less durable, I might start with a layer of regular Bondo.  Then, deeper than I'd ever want to sand away, a healthy layer of Bondo-Glass for overall strength.


BTW, don't trust me on this.  This resin/glass stuff is all still on my to-do list, not something I've actually done.  (Today I'm experimenting with hot wire cutters for the foam part...  I'll get there eventually.)  I have done plaster waste molds and reinforced water putty casts, but not fiberglass.


Paul


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