I have years of working with fiber glass chop (unfortunuately as chop is the worst substance known to man!). Recently have been working on a project where I have need for a lightweight iregular shaped tube, thought maybe carbon would be a good choice. It doesn't need to be exceptionally strong, or exceptionally pretty as it'll be painted. Reasonable strength and lightweight are the goals. (The picture attached is just a mockup, I haven't looked for unmachinable features, proper tangency or areas I may need draft)

1. See pic. Is there any reason a shape like this can not be made using a positive pressure inflatable bladder and two female mold (mould?) halves? Seems I can lay up both havles, alternate the wet-seal top and bottom, insert the bladder, and bake.

2. I see a lot of people (airplane builders mostly) use custom shaped bladders made from garbage bags. Bike builders often use bike tubes. Some people recommend party balloons. Latex, silicon, etc. I've been reading that 10-20psi should be plenty... Do I need a custom shaped balloon? Benifit from one? Get by fine without?

3. Pre-Preg sure does seem a lot less messy. Is there any reason that would not be ideal for this?

4. I can easily cut the female moulds on a CNC, but it's router so I'm limited to wood, ren plank, foams, plastics, etc. Anything but metal. Issue in terms of positive pressure or curing?

5. Not shown in the picture that I have four .75" x 4" aluminum strips that need to be placed on the top/sides/bottom. I haven't looked into how to attach these yet. Molding in seems like it would be ideal as the molds are CNC cut I can assure excellent placement. I saw a lot of warnings about combining aluminum and carbon but mostly when there is electricity evolved. This tube is part of an aluminum and steel assembly that is far removed from electricity. Is corrosion still a concern?

6. How concerned should I be that I've never worked with carbon and am considering this project?

Any direction would be more than appreciated!