I really think you should use paraffin wax to cover any imperfections and smoothen the surface of the ear impressions. I used ordinary paraffin wax on my test shells and they turned out quiet good with good fit in the ear.
Make sure the wax is around 78 degrees celsius when you dip them, this is written in the dreve fotoplast manual so you need a termometer. It is also an art how to dip the wax, it took me many tests to get them good. Watch the 1964 lab tour video, there is an instance when they dip the ear impressions in wax. The cooler the wax is, the thicker the wax will become on the surface, maybe you should raise the wax temperature?
Something you should also try, dip test ear impressions which you are not affraid of destroying, and keep it in the wax for 10 seconds. Lift and you will se the wax layer very thin. This is probably because the wax heated the ear impressions and the wax has enough time to flow down before hardening. So keeping the ear impressions at around 23 degrees celsius or something is also critical when dipping the ear impressions in the wax