Quick update - the plug finally went off to the fibreglassers a couple of days ago.
Had a fair battle getting the large areas smooth having made the mistake of using MDF, then filling & sanding before painting. Once sanded and painted, MDF turns into carpet - all the fibres stand on end. Once I'd sprayed and sanded enough layers to actually stop this effect, I was left with large areas looking like the surface of the moon. I eventually resorted to brush paining several coats of varnish then sanding flat - taking great care not to sand back through.
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If at first you don't suck seed, try drier grain.
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