Whow, this is all really good advice! I just wish you posted this two years ago as it would have saved me a lot of work
Thank you for posting such comprehensive information!

Two small ideas.

Instead of wet layup and vacumbagging, do some research on resin infusion instead. I have done some vacumbagging, but I'll try infusion on my next projects instead. A fiber/matrix ratio of 70/30 has been mentioned by infusion instead of about 60/40 as in wet layup and vacumbagging. It is also a much cleaner and less stressful technique (if you get it to work!).

When doing one-off hulls, make the stations as you have done. But instead of torturing plywood to make a mould, use longitudional battens secured to the stations. Bend the foam (with heat) onto the form and infuse/vacum the inside with the proper glass/carbon/kevlar and matrix (epoxy, poly, vinyl) Install bulkheads and then infuse/vacum the outside.

Check out http://www.fram.nl for some pictures and do a Google for resin infusion.

Just my two cents worth of input on building.