I did a test with the chosen carbonfiber and foamcore and it's no bad at all ! The unidirectional fiber (see previous post) is composed of three layer, two unidir at 45° sewn together covered with a last layer at 45° lightly glued (or just pressed). As this last layer comes free easily it's got to be on top for wetting with epoxy. This weave seems to take more time to suck up enough epoxy to glue well to the foam afterwords, so one must take care it's wet enough on both sides. The good news is it definitly leaves no pinholes and assures a watertight surface.
Mouldwise : the mould is nearly finished since to long ... I needs quite some more craftmanship as I expected. Initialy the female mould is out of wood, glassfiber plates and polyester putty. The putty shrinkes when hardening and is very hard to carve or sand. I now use plaster which expands (slightly) with drying and is softer. I'm looking for a hard wax for the ultimate smoothening, but it must stand the curing at 60°C...
That's it for now, best winds.
