Kathy,
It isn't necessarily a tragedy if the OUTER cover is moldy inside. The point of the outer cover is to protect the inner cover. Was the inner cover damp and moldy where it faced the outer cover? Was the inner cover damp where it faced the bees? Were the bees damp? If the bees were dry, then good.
I have an outer cover that is warped, and instead of shedding the rain, it always let some water collect on the surface of the inner cover. My bees were still dry, but I didn't like it. I retired that outer cover to the job of covering a stack of empty equipment. Hmmmmm. I guess my equipment isn't being well protected from rain, but at least the mice can't get in.
There wouldn't be any mold if there was some ventilation between the inner and outer cover. You could glue some match sticks to the inside corners of your outer cover. That would raise it up enough for air flow, without letting in wasps or moths. Yes, but you say it is warped. Maybe the warping will allow enough ventilation in the future.
No one caulks between the wood and metal of their outer cover. The dampness that allowed the mold to grow could have come from the bees themselves, up through the hole in the inner cover. Is your cluster of bees
nice and big, so there is lots of moisture from respiration?
I wouldn't spend $25 for a new cover until I had tried the match-sticks. Some ventilation up at the top of the hive is always valuable.
Good Luck!
Jeanne Hansen
824 Jacobson Ave
Madison, WI 53714