Here is a picture of a fender off a b5 audi rs4. I am having some shipping from Germany to the US. I would like to make a mold and then use the vacuum infusion method to make some CF ones for my car. I have not done Vacuum bagging and I know this is probably complex. I am working on easier smaller projects to learn, but I like to have time to think ahead about this. In the lower left corner you can see the flange that bolts under the hood, and on the top you can see the flange that bolts by the door. My question is how do you get the insides of those to have nice sharp edges like factory. Will the vacuum have enough pull to get the fabric and resin into those spots? I have searched all over here and the internet in general for anyone that has made fenders and have come up dry. I know these exact ones can be done as a company sells carbon fibers ones for a ton of money. 

can you explain what you mean by have the returns? Where were you thinking of breaking the mold up? Where both flanges meet the outer part of the fender?

to be honest this looks like a very hard/complex to start testing infusion or any technique with