Page Comparison

[1] Acrylic
Yield Strength: 64.8 - 83.4 MPa (Average value: 75.4 MPa)
Young’s Modulus: 2.76 - 3.30 GPa

Flexural Modulus: 2.96 - 3.30 GPa
Flexural Yield Strength: 98.0 - 125 MPa (Average value: 109 MPa)

[2] PETG
Yield Strength: 28.3 - 58.6 MPa
Young’s Modulus: 1.10 - 20.3 GPa (Average value of 2.65 GPa)

Flexural Modulus: 1.17 - 2.76 GPa
Flexural Yield Strength: 39.2 - 88.9 MPa (Average value of 69.5 MPa)

In short, Plexiglas is a strong enough viable alternative for the side walls of the cover.

Gel-coat
Protective finishing layer for composite surfaces.
Leaves a hard smooth surface good for sticking on adhesive.
Requires sanding and buffing for a smooth surface.
If painting the cover, apply gel-coat first then paint over it.

Source:
[1] http://www.matweb.com/search/datasheet.aspx?bassnum=O1303
[2] http://www.matweb.com/search/datasheet.aspx?matguid=4de1c85bb946406a86c52b688e3810d0

Solid insulation foams from local hardware stores are good mold making material.
Can glue multiple sheets together to increase thickness for desired mold shape.

Volume per sheet: 2304 sqcu. in
Front right and left wall: 182.22 sqcu. in
Rear right and left wall: 289.66 sqcu. in
Front lid: 790.32 sqcu. in
Rear lid: 2521.2 sqcu. in
Total mold volume: 4255.27 sqcu. in
Requires 2 sheets: $40 total

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