Hi
Im currently making a large foam mould for uses as a nose cone for a small single seat racing car.  

We have used Easy Composites Low Density polyurethane foam to fill in gaps between our MDF skeletal frame.
I would like to make sure that I have the process correct for creating the mould as I only have one shot at this.

For the Plug once sanded body filled and completely finished i'll paint on a layer of EG60 Epoxy tooling gelcoat and allow this to fully cure, then apply at least 6 layers of the Easy-Lease Chemical release agent, followed by at least 2 layers of mirror glaze mould release wax. 

Then im using 4 layers of 100gsm CSM fibre glass to create the mould from which I can infuse upon.

Is this process correct or is there anywhere I should make alterations please let me know.

Thanks
Charlie

Epoxy tooling gelcoat is going to be an awful pattern coating, it is designed to be quite tough and will be hard to sand flat and polish. Use EC's Patterncoat Primer initially, and then the High Gloss if you are after a glossy finish.

Also, you mention that you're using a 100g CSM to make the mould, but EC don't sell a 100g powder bound CSM. Are you sourcing it from elsewhere, or are you planning on using regular CSM with epoxy resin? I can tell you that will not work well...

If you are just making a mould for infusion, I think ditch the idea of using epoxy altogether and use Unimould instead. Much easier system to use and will deliver excellent results for infusion.