The "mechanical lock" has me nervous because I am making the mould around the edges.

I'm going in for the "kill" tonight so well see

COmplicated projects as a starter will teach you lots so as long as its within your ability and learning curve then its not such a bad idea.

Im thinking of doing similar with my headlights. 

If it were me, id sacrifice a second hand set of lights for the moulds. yes you can use modelling clay and waxes to fill holes and build flanges but it might be easier to spend more time. eg filling the grill area with filler, plasticard or similar rigid material to fill the light holes and do the flanges.  Then sand it all smooth, seal the surface how you see fit ready to make the mould.

Might sound like a bit more work but more work on the "plug", the less work on the mould.  Its upto you which way you do it really.

Just be aware of your angles around the tight curves and edges so you dont get mechanical lock.

You could make the attachment parts using some trimmed Pre-preg angle cut to fabricate the part.

thumbs up, keep going and show me your result, i think it will look great.

best regards mhd alghoul mhdghoul@hotmail.com youtube channel :atmospherejo link is http://www.youtube.com/user/atmospherejo?ob=0&feature=results_main

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