Well, some news to report - hot glue moulds break down after a few uses, no matter how much mould release is used...
But, on the positive side - learning happened!
Basically, even though I slathered wax onto the mould surface, the polyester resin dissolved little pockets from the mould, forming voids that were filled by the resin on the next cast and so on.
Two things happened -
(1) I tried something new and learned that it didn't work, and
(2) it gave me the impetus I needed to try an expensive silicon mould.
Here in New Zealand it costs $140 (about US$115) for 2kg of silicon, not counting freight, but I am sooo pleased with the results! Thanks to watching a couple of YouTube videos making the mould went without problems, and it is holding up beautifully. It is platinum silicon, not sure of the brand, but for any Kiwis on the boards, NZ Fibreglass in Auckland are awesome to deal with. Order over the phone, and the guys you talk to have been using this stuff for years. really quick delivery as well.
Anyway, summing up - hot glue will work in a pinch, but from now on I'll be assembling moulds until I've got enough for a pour of silicon. Hope this thread has been of some use.
Cheers, Phil