1. To begin, find some one to sit and talk the project trough with.
Try John Hammond at Mainland. 909-923-4353. They build cast aluminum molds in your neck of the woods and know a lot of molders.
2. See above
3. Contact ARM (Association of Rotational Molders) http://www.rotomolding.org
4. Tolerances are not typically as tight as you may be used to. Dependant on part size, shipping a lot of air with the parts.
5. Secondary operations
6. Graphics, inserts, special material, exceptionally low quantity.
7. Absolutely reliable.
There is a lot more to it, of course. Bring someone in with roto experience as soon as you can.
Will answer any other questions.
Genex Plastics, Inc.