Guys,

I have had an unexpected project come up. I had a little bump in my track car last week. Luckily, it has only caused damage to the front bumper and front splitter. Other than that, the car is A-OK. 

So I have decided that i will make a composite front bumper. 

Thinking out loud:

The style of the bumper is very sporty and aggressive with sharp edges but fortunately there will be no issues with mechanical lock so I will be able to make a single piece mould that should release with a little tug tug. When laying the first layer of 2x2 CF fabric I think it will be next to impossible to avoid creasing and folding to the cloth. Is there a solution for this?

Could I stencil out individual pieces of cloth and align them together with a small overlap or will that translate into the finish piece.
Or the other potential option is the make a forged piece.


Please let me know your thoughts.

Thank you.

Thank you for your reply, this is helpful.

And yes, with the above technique, my main concern was as you say, cutting stencilled pieces of CF cloth and it fraying the the point where its impossible to handle. Normally, with a single piece of carbon fibre cloth, I use masking tape to mark my cutting line a cut along it. But of course you cannot do that if you have separate pieces as the masking tape would be incorporated into the final piece.

I cannot use prepreg as I don't not have access to a large oven.

Thanks.