So I've decided to make my first project with carbon fiber a difficult one(not smart?). Ill post pictures as I progress and advice as to what I'm doing would be appreciated.

The idea is to make a mould that wraps around the edges as they can be seen while on the car.

The clay in the front of the light is to fill in the cosmetic groves that the carbon probably wont lay into, should I just fill them in with Gel-coat and sand them off the mould, or try to fill them in like I have now? The clay is hard to smooth out nice and ill probably have to sand anyway.

I would like to make this a repeatable process because I'm practicing on a used pair of lights first and if it comes out good Id like to do mine.

prep for mould making so far

Ideally you want a flange all the way round.

However you might get away with a flange at each end, one flange for the resin feed, one for the vacuum connection.

Then envelope bag it.

Ive done envelope bagging on a couple of moulds and you get virtually zero resin underneath the mould. Remember the vacuum pump is drawing a force through one axis so the resin has no reason to under the mould when the forces applied are sucking it in the part and out other side.

Only bit you will get some resin weepage is due to gravity at the sides due to your zero flanges.

What i did on one of my moulds was sand the putty smooth as it has glass strands that could puncture the bag, then coat it with a thin layer of old resin i have.  I then gave it a quick coat of easylease just in case. (Matt and Paul think i have a drinking problem with easylease but i just throw it everywhere and do loads of layers just to be oversafe).