Hey guys 
we started to brain about our first mold,.. a mold for a CFK door of a Mazda RX7 FD3S
and we found a lot of tricky problems..
here are some pics of the door
first step was to strip the door compleatly,..
after that we found some bad things,..
how would you do a mold for it ? we have no idea, because, you get no carbon in this small finn..
next problem,.. the shape of the window frame,...
here is a sketch about the frame shape,...
after more than a hour of brain storming this stuff become rudimentary :/
here a brain storm sheet ^^
we cut out the door frame... not really cut,.. we drilled the welding spots and removed the adhesive between all metal sheets without deforming any part...
OK now we have the inner and outer side of the door,.. thats an easy mold,..
but the frame is tricky !
we want to use a (I dont know the englisch word for it, maybe its the same like in german - a lost core?) out of polystyrol foam ?
and we change the shape of this frame...
what is the best solution to get this polystyrol core?
first an RTV positive mold, then a negativ mold and out of this mold the cores we need?
why diddn't we start with a small piece ? or some easy stuff lika a bonnet :/
ok now I was drwaing about 1.5h on this stuff ...
good night