Well I think it isn't alligatoring of the gelcoat but styrene attacking the paint and plastic. You must not have had a good barrier with your wax and PVA.

If you want to have no risk of this happening again use epoxy for your mold. (after you wax and PVA)

Fred  

Okay so I just completed my first mold and everything looked perfect...from the outside. As I pulled the part from the mold I noticed the part had been completely alligatored through the OEM paint and into the abs plastic part itself.

What caused this?! I didnt use too much MEKP I actually used a little less than I was supposed to. I waxed and PVA'd several times while useing the proper precautions of waiting to dry in between coats. The only thing I didnt use that could have been a causing factor is a hi-temp wax. I actually left it at home so I used Honeycomb wax or HoneyBee wax..something like that. It comes in a yellow container.

I will be producing more molds from plastic parts and dont want this to happen again.

Thanks for the help!