I am trying to make a wing for my race car. My ultimate goal is to make a mold so I can make a hollow wing for me, and have the ability to make more for my brother and dad. I have the XPS foam core that was cut out in the profile that I want and I have been kind of stuck as to how to go about prepping the foam so I can make a mold. 

My recent thought has been to cover the foam in a carbon skin, use mylar over the carbon to keep the surface smooth, and vacuum bag it during it's cure. Once it's cured then use the skinned wing as the part to make a mold from. Will this work?

Is there a standard practice to make a wing mold that I just don't know about?

Thanks for any help!

Patrick

For low volume you could just cut a few more XPS cores and laminate like in this video:  How to make a carbon wing    You could use a similar process to make a pattern using woven glass or similar as the reinforcement.  Then, once you have a good pattern, you can make  2 part mould (upper and lower) using the Uni-Mould System.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant