1. Female Aluminium Patterns were machined the same size and shape as the internal cooling required for the engine. These were done from aluminium for accuracy and because of ease of manufacture.
2. Once used for casting a male pattern in aluminium powder / epoxy resin the female patterns are not used again.
3. Alumium powder and epoxy resin were cast over the machined aluminium female patterns to make a male pattern (as seen in the front of the photo). 80 durometer Poly Urethane pressure patterns (seen at the back of the photo in brown colour) were cast over the male patterns.
4. The carbon used for one side of the cooling duct, 100 gsm carbon cloth cut at 45 degrees bias is laid out on silicone paper ( glad bake). Epoxy resin is added ( LC 3600 )
5. Another layer of silicon paper is put over the top.
6. The epoxy is spread out between the sheets of paper.
7. The cloth is left rich with resin. The excess resin fills the gaps where the cloth can not be pushed over the moulds.
8. 1 Vertical layer of carbon fibre cloth is placed on the pattern.
9. 1 horizontal layer is added, and so on.
10. All the pieces of carbon cloth are shown laid out on the male patterns.