Guys,

I have had an unexpected project come up. I had a little bump in my track car last week. Luckily, it has only caused damage to the front bumper and front splitter. Other than that, the car is A-OK. 

So I have decided that i will make a composite front bumper. 

Thinking out loud:

The style of the bumper is very sporty and aggressive with sharp edges but fortunately there will be no issues with mechanical lock so I will be able to make a single piece mould that should release with a little tug tug. When laying the first layer of 2x2 CF fabric I think it will be next to impossible to avoid creasing and folding to the cloth. Is there a solution for this?

Could I stencil out individual pieces of cloth and align them together with a small overlap or will that translate into the finish piece.
Or the other potential option is the make a forged piece.


Please let me know your thoughts.

Thank you.