Cool stuff. I've done carbon, by itself, not with a Kevlar mix. Gets a bit expensive, with the epoxy resin, and all. Do you have a vacuum system? how many oz. cloth is it? Easy to drape over curves? It really looks cool!

Nope, no vacuum (well, at least not yet) for this project. Spec.s on it are....2x2 Twill 50" 3k 5.5oz. I could have gotten it in a heavier weight however I just wanted to see how easy it was to manipulate and drape by going with a little less ounces. It appears very flexible while still holding it's pattern.

That should be flexible enough, but you'll still need some type of 'support' to keep it in shape while it's curing. That's the beauty of vacuum bagging. I've tried wrapping, shrink tubing, and other methods for different shapes, but vacuum works for all!

We've run into that problem with certain types of leathers/fabrics/veneers in furniture restoration. I have used a "tacking glue" glue method for this which keeps things in place while they cure. It is a clear UV inhibited glue that we can set almost instantly. Just a few dots of it here and there should secure everything in place.

Step by step instructions with pictures would be nice . . .

And you are the second person that has asked for that today, ha, ha. Yeah, should not be a problem. I've been studying about this stuff for 2 years now and I think I've got a few things figured out that should allow an open layup method to be fairly simple yet yielding a strong part.

when I first saw the title of this, I was thinking "Hmm not so sure about this". After reading through your thread and seeing the images, I'm sold! This is an awesome build!

Ha,ha, anytime your main tools are a Sawzall, circular saw, and a rivet gun it's always suspect..... Hoping I do as well with the wing build.....

So today we begin "wingin' it." Well, could not resist that. And the creation begins.... Went to good ol' Home Depot and along with other shop stuff picked up a 4 x 8 sheet of pink insulation. With a process like this you could use the blue, pink, or yellow foams for your shape. If you use the yellow stuff I would remove the foil faces. So why not use white foam? The typical white foam just doesn't shape like the other foams. They are easy to cut carve to a great degree of precision. So just what are doing to make this wing? This process will be called the "lost foam" or "carbon wrap" (not to be confused with vinyl surface wraps) process. The idea will be to get a foam shape like the wing I want, then wrap it using epoxy resin and that great looking carbon/kevlar wrap I showed earlier. It has been requested (uhhhhh, more like demanded) that I do this step by step so the pictures will have some details for that.

Are those kerf cuts progressive in size or varying in distance from one another?