Specifically, my idea was to use the CNC to cut the part itself out of the polystyrene foam such that I have a positive mould, which I would then coat with a thin layer of epoxy. I then intend to use the Uni-Mould system, treating the epoxy-covered foam as a regular part, to obtain a negative mould. Any suggestions or reasons this would not work? I am especially concerned about the layer of epoxy on the polystyrene foam reacting with the epoxy-based gelcoat and hindering its release.

) Roughing operation.

2. Between the finishing pass and the resin infusion, is there any surface prep you do with the gelcoat layer? Do you sand the gelcoat on the mould or apply another layer? I noticed that you achieved a smooth finish on the wing mirror surfaces, but I assume that this would not be possible if you lay the carbon immediately after the finishing pass.