yes,i think i used a 1/2''roundover bit on the inside edge. used a mold release wax/paste. you could use plywood or mdf with formica for a one off mold. the pvc board i had was smooth on one side wood grain on the other. as far as the i/o goes i can't help you that was the first thing i got reed of. outboards for me. in my boat the motor mount for the i/o was about 4-5 2x6 stack on each other then glassed in. seems to me your giving up a lot of space with a i/o cover,leaning post and a cc. or are you going with a pilot house?
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