After the cardboard mock up is compete, how doable would it be to lay fibreglass over is to form a hull?
Hi Simon,
Some pictures of your build would be helpful.
Depending on if you want to keep the cardboard inside the fiberglass or not decides how to go about it.
I've coated a cardboard hull with class cloth and resin some time ago; as I didn't want the cardboard to stick to the resin, I coated the outside with molten candle wax, which was smoothened with the help of a hair drier (a heater/paint stripper works too, but you have to take care not to set things on fire...)
Once I was satisfied with the appearance of the surface, I glassed it with glasscloth and polyester resin, epoxy would be my choice of resin nowadays, as I've developed an allergy to polyester.
Once the coat of glass and resin is sufficiently thick, let it set for a couple of weeks in a warm environment.
Once it's fully cured, heat up the hull until the wax gets soft and pull the cardboard out of the laminate.
My cardboard hull didn't survive, as I'd used hotmelt to assemble it and the joints came loose when I heated things up to remove the cardboard hull...
Here's a picture of the polyester hull:

As it was my first attempt working this way, I overdid it on the layer thickness (2 mm+) and the hull was very heavy for it's size (75 cm), so I never got past testruns to establish a suitable motor.
I later went on to build a larger version in ply:
http://www.modelboatmayhem.co.uk/forum/index.php?topic=34033.0If you used cardboard with a hard shiny surface, I would not try to incorporate it into the hull, as the resin will not fully penetrate the cardboard.
The gray, open structured cardboard however, will absorb the resin like a sponge, the first layer of resin will completely disappear into the material, leaving you with a nice base to laminate the glasscloth onto.
Mind you, making cardboard soak up the resin will make for a rather heavy hull, most likely with the same result as my first attempt; too heavy to sail properly, as it'll sink in too deep.
Let me know if you need more information on how to go about it.
Regards, Jan.