Update time! I have begun the coding phase of the project this weekend. Thanks to the sage assistance of you forum goers, I have succesfully gotten the
Axon microcontroller to control my SSC32 board and have gotten it talking to the Bot Board II as well. I treid getting the
PS2 wireless controller talking directly to the
Axon but in the process something went wrong and now the wireless module refuses to work anymore

.
So rather than risk a frying a new
PS2 controller on the
Axon, I have set up the Bot Board II to receive the
PS2 data and then report it back to the
Axon. That code is complete and tested as far as I can without a working controller.
As per the fiberglassing, the cnced mold was sized perfectly so that a shell formed around it would snap fit to the size nessecary. That menas the vacuum formed shells should fit snug as a bug. Ideally the same would go for any fiberglass built over the mold as well.