I have no idea about the mold with lexan, I've only used and been around fiberglass molds. I do, however, know that building the mold is a huge process as I've been watching the process from some guys on the forums that are designing and building lexan bodies, and the mold making and then forming the Lexan was a VER Y long process for them, keeping in mind that this is someone where the money is not an issue, so I would think for an individual it would take quite a bit of work to get it done. Let me know how it goes, I would love to hear from you if you decide to give it a try. I'm all in all the time for guys who do their own custom fabrication.