+x+xProbably obvious but, just in case, you will have to make a male mould otherwise the cover won't fit. So, make a female pattern/plug without altering the existing part, fettle this to your satisfaction, take a male mould from this with which you can make the cover.
An alternative method would be to simply make the cover directly from the part, then flow coat, sand and polish. This method was used by Carbon Weezel to make my bonnet and boot a few years back with perfect finishes.
Thanks for the replies. Steve, can you enlarge a bit on the flow coat idea? Would that be wrapping Carbon fibre directly onto the aluminium frame, then remove and flow coat it (inside of female mold)?
Lay up carbon on to the aluminium part. When cured flow coat, sand and polish the surface that will be visible. No patterns or moulds to be made.