According the the MSDS sheet for Smooth-Cast, it's actually not a huge threat in terms of vapour inhalation, apparently. Unless you're experiencing prolonged expose in excess, in terribly ventilated areas, that is. Here's the Material Safety Data Sheet for Smooth-Cast:
http://www.eagerplastics.com/sc300a.htm
Unlike resin, I don't think it will be a threat to others in your house unless they walk up to a batch, stick their nose in it and/or lick it. That said...
I'm not sure what your reason is for not wanting your family to know what you're up to...however, unless you're making the armour in cognito and will be arrested if caught, then I do strongly recommend informing your other family members about your project, and your concerns about using a toxic material, like Smooth Cast. While it's not exactly cyanide, I'm going to take a shot in the dark and assume they don't know what Smooth Cast is. If they don't know about it, and can't smell it, then they're not prepared for it. Being informed about materials that release harmful (if unscented) fumes is very, very, very important. Never take risks with chemicals.
But in any case, Workplace Hazardous Material Information Stuff aside (*shudders* WHMIS...) there are several other kinds of materials to use rather than Smooth Cast. For example, I"m using plaster wrap on the inside of my armour and your basic acrylic medium instead of resin to coat and protect the outside. None of the materials I use are toxic and it gets the job done. I can't use resin either since I'm not comfortable exposing anything remotely dangerous to my fellow tenants/landlady friend.