Hello,
I'll get straight to the point. I'm trying to make this OEM grill with faux vents into this CF one.
When I make the mould, should I cut the original so that when I lay the cf it has an inner edge to bevel around?

OEM grill


CF grill


Where it'll go

The aluminium honeycomb grill used against the carbon looks mental.

You could cut it out, but it has to be a very neat cut.
You could also fill those diamonds and cut the hole out of the part. Then quickly rub the edge with some 240 grit to give it a slight radius. A coat of clear will naturally round it off a bit more.

Thanks Cactus. I'll go with filling in those diamonds as I don't want to cut my original. Do I use modelling clay from art stores for that?

I would use Bumpersoft.