Hi Royce,
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Hey have you ever done a silicone pour into a 6 foot doll mold ?
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Yup I will need to go "upstairs" with a big bucket 60 lbs silicone to pour that doll, I know.
I have a local supplier for alignate, bandages and plaster, due to this I can buy for prices not much can get this gear.
A release agent is used for the alignate, the release agent comes on the skin first and thus provides some protection.
If you want to go as safe as possible then it could be a deal to pay more use a very skin safe alignate as e.g. alja safe from Reynolds
http://www.reynoldsam.com/index.php?cPath=3_1185
The only way to omit the whole casting is going with modern rapid design technology's that involve renting a 3D scanner which maybe affordable
http://www.3d-scannen.nl/modules.php?name=Content but what do you with such data? I think you will end up having the model printed by a huge 3D printer but I think that will set you back several K pond sterling.
Mytime & Helen & Carmen