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I've designed an build composite shells for automotive racing as well as one peice hulls for boats. Although wood is a simple medium i have moved from it and found that aluminum and far more versitile especially considering is degredation and corrosion resistance is far greater than wood. Not...

Wood is used in the process of building the plug or the mold you never use mood in the final product unless youre making a ****ed boat. Aluminum strips or bars molded into a frame for the final fiberglass product should yeild enough strength for all the critical points such as hinges, latchs...

Not necessarily expensive if you know how to work with wood. Sure doing a Metal plug or foam plug can get expensive but wood is a cheap and reliable alternative if you have a dry place to work. A chopper gun can be quiet effective if you have a plug and mold to compress the chop afterwards or...

Yeah but it's fun and messy to do it on your own...

Theoretically, if he were to make a mold and spray in the fiberglass chopped mat with the proper resin it would have the build and strength of that cheap children's playground equipment from years back. Not sure how LIGHT it would be but it could hold a rather "healthy" individual.

Cause they can. Unfortunately that same mentality in a fat Air National Guard soldier has my hard top caved in a bit... :(