Hi Ben,

I would seriously recommend investing is some Eurotrax wheels. You can purchase them from Sydney based A Class sailor Glenn Brown (Blue A Class from Pittwater / Kurnell) and build your rollers.

Yes the wheels will set you back a few hundred $$$ but your back will thank you. After years of using wheel barrow tyres and those lager plastic rollers, I purchased a set of Eurotrax for the Capricorn and will NEVER go back. I can tell you now that my 180 kg F18 will be easier to move around the beach solo than your 65 kg Mossie with wheel barrow wheels. The A Class sailors that use them can move their boats around gripping with the fingertips of one hand.

As for cups, use your hulls as a mould and lay fiberglass over the mid point (ballance point) of the hulls. This will give you the right shape and then line with carpet.

I am not a fiberglasser but I believe you wax up the hull so the glass does not bond to the hull. Seek advice from someone who has worked with fiberglass.

http://www.intocom.com.au/ic/eurotrax.htm