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Hi guys,
It's been a while, but I used to build the carbon fibre landing gear doors for the Airbus A320 when i worked at Hawker De Havilland.
Not sure where you would get the material, but the procedure goes like this:
The material we would use is called "pre-preg", meaning the material is already impregnated with the resin. This material is layed out, layer by layer, onto a metal mandrel in the shape that you want. The layer that makes contact with the tool is the "smooth" side. The layers would be vaccuum compacted after every few layers.
Once all layers were applied, the final bag was prepared. This consisted of a layer of "peel ply", to prevent the rest of the bag sticking to the job. Then a layer of fibreglass material. This absorbs excess resin from the job. Then some layers of plastic, to stop the resin getting any further. Followed up with breather cloth, and the final thick plastic bag to seal the vaccuum.
This whole assembly is rolled into an autoclave, which is basicallly a very big pressurised oven. Its cooked for a few hours at high temperature and pressure.
There are different procedures for making seamless tubes, but I think they might go beyond the ability of the home user, as they are woven strands.
Clear skies,
Shane
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