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http://www.talkcomposites.com/Topic20270.aspx

By Davo456 - 1/17/2016 12:56:11 PM

I've skinned 3 parts in the past, and am reasonable at diy, so I'm trying to expand my skills and produce a better job than skinning aluminum.

I am trying to make this dash in carbon using vacuum bagging (the skinned version I made earlier was ok, but I think I can do it better), and was wanting to move some of the dials around within the overall boundary.
http://www.talkcomposites.com/Uploads/Images/4f78cc2e-9ce8-4aa3-8939-2b7f.jpg
So starting with a sheet of polypropylene, I was going to lay 3d printed circles for each of the dials where I want them and a 3d printed edge of some sort around the exterior.
using plasticine to stick them in place.

The original plated steel planel is 1.6mm thick.

To get something sturdy in 199g 2x2 twill carbon, how many layers would I need to have ? I presume I would need it around 1.6mm thick again as its 7-800mm long.
how thick should the edge and circles be if I am going to vacuum bag this ? 
Will covering the 3d ABS plastic in PVA mould release agent be enough to protect if from the resin or do I need to cover it something else ?
By Dravis - 1/29/2016 8:51:26 PM

-- cover the whole sheet with masking tape!    Draw up the shape and the holes on the masking tape .. then cut with the jigsaw about 1 mm inside the outline of the holes -- then sand out to the edge.
That way you will have very nicely finished holes with no cracking.

The masking tape will protect the surface of the Carbon .. -- You can cover both sides with masking tape if you use an electric jigsaw .. that way the jigsaw will not scratch or score the mirror-surface  (from infusing on the glass-plate.)