Stevey, I really hope you decide to go through with these the fiberglass way. I think OEM quality skirts would be way cool. Like you just said, making them will be difficult. You will most definitely be going the extra mile but in the end the results could really be worth it. If you have the time and you get it done right, you might be able to make a few bucks selling additional ones off to other cobalt hypermilers.
I, too, have zilch experience with fiberglass but to speculate, you may want to jimmy rig some ghetto skirts first to help you make your mold. I would guess that either wood or a type of styrofoam may work best for a mold. Best of luck.
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