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How to Make Carbon Molds

Carbon fiber pieces are extremely strong, durable, expensive car pieces. Usually used in racing cars and bikes, these parts can be hard to find and cost a pretty penny, especially if you've customized your piece. When something breaks, it's much cheaper and easier to cast a mold of the piece rather than purchase a new one. For full preparation, cast a mold for each of your carbon fiber pieces before installing them. This way, you don't have to work with a broken piece for your molds.

Things You'll Need

Carbon fiber part
Mold release wax
Acrylic glass sheet, such as Plexiglas
Mold-making putty gel, any color
Paintbrush
Mold-making putty, grey
Utility knife
Soft cloth

Instructions

- 1
  Rub a piece of mold-releasing wax all over your carbon fiber part, coating each and every surface of the part. Let the wax dry for about five minutes; then add a second coat. Repeat, adding up to six coats of wax. These coats help give your mold a smooth finish.
- 2
  Put on eye goggles and rubber gloves. The gel and putty are somewhat harsh and should not touch your skin.
- 3
  Place the carbon fiber part on a Plexiglas sheet. Rub the area all around the sheet with release wax, adding two coats to the Plexiglas.
- 4
  Dip a stiff-bristle paintbrush into mold-making putty gel. This resinous, gluey gel comes in dozens of different colors. Choose a color you like best or color code your parts for easy access.
- 5
  Brush a thick, even coat of putty gel all over the parts of the carbon fiber part that aren't touching the Plexiglas.
- 6
  Allow the first gel coat to dry for about five minutes; then add a second. Continue until the edges and angles of the part are blurred under the gel. Let the gel dry for about 15 minutes.
- 7
  Knead and warm some grey molding putty between your hands. Push and squish it down over the gel mold, really pressing it into place. Allow the entire structure to cure for about 24 hours.
- 8
  Peel the mold up from the Plexiglas, and gently pull the part from the inside of the mold. It should come away easily.
- 9
  Cut and smooth the edges of the mold to avoid bumpy carbon fiber pieces. Wipe out the inside of the mold with a soft cloth.

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