Seen and had this problem many years ago when I was starting with resin casting and trying out all sorts of resins and rubbers. I think I could sum up your problem with one word, Polyester.
Polyester resin is ,in my mind for some other work ,not model castings or jewellery castings etc.
Your moulds are fine , but the polyester reacts to the rubbers and causes a pattern called Tryping, where the resin casting has all the lines over the surface once set. Looks like the surface of wet glue of a joint that has been pulled apart.
You need to get on to a clear urethane resin and try that out, if this cures the bad surface than I think the other problem with the smell of the resin will be solved as well. Give your moulds a good clean in warm soapy water before you use the new clear Urethane resin. Good luck