Can anyone explain how to get a perfect join in 2 pieces of carbon fibre material when doing carbon fibre skinning?

The best way is to use our ProFinish Carbon Fibre 2/2 Twill as you can cut neat edges with little or no fraying.  We always recommend the second sheet overlaps the edge of the first so you don't get any gaps.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Yep ... If the part you want to skin does not have too much compound curvature, then Pro-finish cut with very sharp scissors (Like EC's CF/kevlar ones) is the way to go.

When skinning, overlapping the edge can sometimes leave a ridge, so I try to lay it "edge to edge" even though it takes a lot of careful handling-

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Hi Warren,

                 When using the infusion process for max strength how much overlap is needed on carbon twill fabric on adjoining sheets? If the stack is say three layers thick should the joints be staggered so they are not in alignment verticaly?

Trevor

2" is normally the recommended overlap. 

50mm/2" is about right.  In theory, you should stagger the joint but in practice for most panels it makes little difference as the additional thickness in that area will mostly compensate for the joint.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant