How many layers of cf ( total thickness in inches or mm) would you make a cosmetic roof cap for a car? Also what materials would i use to make up the thickness of the laminate if i mold off the car?
Heat up some kind of sheet plastic like acrylic or abs with a heat gun to the shape of the roof then mold directly off that ? What type of plastic can be shaped with low temperature heat and then be molded off of? PE sheet?
Thin Sheets of HDPE could be conformed to a roof and as a bonus they don’t even require release agent for demolding.
but trying to get any resin/glass to build up the mold on the back side might cause some issues 
3m does make a low surface energy transfer tape FOR PP/PE plastics…might work it you build up a structure in the back, or even a thicker layer of HDPE.
When you say roof cap, I assume the final product will be bonded to the existing roof right? Since I never made a part like this, wouldn’t 2-3 layers work since it is just cosmetic and the existing roof will be there for structure? What kind of car is this for?
any chance of putting pics of the mould up. it on my list of things to do on my car
from what i have seen on the honda forums.they are pulling the mould right off the car.so you would wax/pva the roof.then pull your mould.so the 3 layers of carbon wouldnt effect the fit.3 layers of carbon is .030 thick if you are using 5.9 oz 2x2.
pulling a mold right off the roof would be ideal, but with some roof shapes fit could be an issue if there are any sharp angles or tight radii.
I need to find a doner car to make the mold but yea i think on this particular car there wouldn’t be an issue with fitting. ( famous last words lol).
The other issue at hand is how to bond the roof cap to the oem steel roof? I can see it ok to use a thin line of black silicone to fill the seams in the front and back by the windows. Should the factory paint job be scuffed prior to bonding the cf laminate to it?
How many gallons of PVA do you think would equal .030" for an average coupe car roof?
I have seen ams pop rivet and bond a skin on to a evo, the pop riveted down the sides where the roof rails coverd if i remember correctly.
When i was working at a composites bath room specialist the used sikka flex on the panel they stuck on a fake tile wall, and when i mean stuck, it stuck one had to be pulled off because it was wrong color, it took 8 hours. id use that if u can find it.#
I will find the ams thread for u to read