Hi I'm a complete carbon fibre newbie so please bare with me. I'm looking for some adviceregarding creating a custom case from scratch. I do not have a case similar to anythingI want which is why I'm planning to make a case out of carbon fibre.

the case I would like to make needs to have internaldiameters of around 142cm Long, 16cm Wide, 6cm High. to allow for foam padding myquestions are.

1. roughly how thick do the layers of carbon fibre need tobe to provide protection to avoid damaging the item inside when stepped on andnot to warp if the case is leant diagonally - when I carry it in my car.

2. what would be the best way /material to make a mould outoff - I would ideally like all the outer corners to be curved so I feltMDF/wood may not be suitable. I'm not too concerned about the appearance of theinner corners of the case as it will not be seen however the lip where the case2 halves of the case join together will be seen so I would like them to be veryclean and tidy.

3. I plan to fit Hinges and locking fasteners onto the longestedges of the case I guess that if I made the mould 3cm high I could use themould twice so the top half and bottom half would be the near identical. isthis possible or would I have to make 2 separate moulds?

4. as stated in question 3 I will need to fit hinges andlocking fasteners does anyone on the forum have experience or can recommend asupplier also advise on the best way to fix them to the case.

5. roughly what materials and quantities will I need toorder.

wow reading all the above makes me realise how much of anewbie I may be. Thanks in advance

Rudger.