AC, PS and, your kidding, power Windows?, for crying out loud??!!! Sheeshhh, yeah that might impact production costs alright!
That being the case there are clearly looking for a limited up-scale market with some exclusivity. It's not a bad game plan.
A mold is a mold, perhaps a bit more contour than some but not a major factor in cost or assembly I would think.
Just a guess as to what the frame would be, round, square, whatever, it's just "stock" you buy from the metal guy. It's not going to be a stamped steel or whatever like GM used originally. It's all the "nice stuff" that will drive the cost up. Insulation for the AC, sound deadening so as not to offend the occupants, more wiring for the all the extra stuff (like power windows, interior lights, etc.), a thicker glass shell than the originals (for strength) and it all add's up to MORE WEIGHT (and cost).
This is gonna be just like in the 60's, any decent Cobra replica worth it's salt is going to kick the ass of this over weighted pig.
Of course, the Vette driver won't care, what with the AC on and the stereo blasting as he lowers the window asking for some Grey Poupon.
License fee should be a small item, it didn't have a major impact on SPF Cobra prices after all (and much cheaper than a team of lawyers).