the entire car underside is flat, I made the diffuser from scratch and of cause it had to be in V weave.

Haven't posted on this forum in a loooooon time but i think this is really worthy. I love what you are doing here Andy! What engine specs are you going for?

Often you are best designing the part from scratch rather than copying the alloy cast original as they can get away with more complex shapes and logos in a cast part than composite.

If i made a camcover in the future it would be my own design, based on factory dimensions so its easy to mould.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

I looked carefully at the rocker cover with the intention to make canon ones (I had carbon ones designed and made for my Ultima by Reverie around 10 years ago)... however the noble ones are way too complex a shape to attempt and they are sided so would have been a huge amount of work... Carbon inlet manifold is a possibility though.

Thats interesting detail Warren.  Always appreciate your knowledge

Ive looked into doing cam covers before. It all depends on the Oil sealing arrangements on the underside.  To get a nice cosmetic smooth upper, you may sacrifice a smooth lower if you want to keep a simple one sided mould. 

However you can skim a flat face onto the bottom of the carbon if you make it oversize.  If the internal oil detailing is complex you can make an inner and outer mould, 2 carbon parts then bond together.

Obviously a suitable temperature resin system is a must.

In my opinion you would also be wise to incorporate a layer of kevlar in the layup to prevent any cracking issues with heat cycling or potential burst issue with a thin camcover if you have a heavily pressurised crankcase due to a breathing issue.

Sumps I would be concerned about the consequences of a minor impact, even with kevlar when compared to metal sumps.  Many metal sumps will just dent or crack thus avoiding any catastrophic instant oil loss.  However a composites one would likely cave in and maybe hole but at least have lots of cracks.

Also permenant immersion in engine oil and combustion products would be a challenging environment for the carbon/epoxy to survive.  You may need a inside coating or different resin lining. Vinylester resins have a very high chemical resistance to oils and petroleum based products so may be the solution for chemical resistance.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

How about a sump or cam covers etc?

Hi
So you are doing something like monocoque? because I am not sure what more can be done here with carbon maybe wheels

~~~Everytime I hear sound of demoulding part I have eargasm~~~