Just some recent pics... The molds have been done, now I'm making the fiberglass resin plates. The resin comes in liquid form, which you need to mix with a catalyst. The ratio I use is about 1 teaspoon of catalyst for every cup of resin. The mixture cures up in about 30 minutes and you can pull it out of the mold. Be very careful because the resin becomes very hot during curing.
I had fun doing this because it's kinda like baking! Anyway, the pic below shows me preparing the resin-catalyst mixture.

Next, the resin is poured into the mold, and is left there to cure. You can see some of my other half's projects in the background... :P
This is how the first version of the "Minas Morgul" looks like. I'm currently working on a new version for the final presentation.