Shop products (USA) ► Shop products (EU) ► Shop products (UK & World) ► Further information and links ▼ In this step-by-step video tutorial we demonstrate a method of making high performance carbon fibre downforce/aero wings for motorsport without needing a mould. Instead, carbon fibre is laminated onto the outside of an XPS foam core which has been profiled using a hotwire cutter. Mylar is used to smooth the carbon fibre and a vacuum bag is used for consolidation. End plates, which include aluminium mounting inserts, are made using Nomex honeycomb bonded to carbon fibre sheet. 00:00 - Introduction 01:37 - Hotwire cutting XPS foam core 04:05 - Machining wing inserts 05:21 - Cutting Mylar surface film 06:14 - Prepare the vacuum bag 06:31 - Preparing the carbon reinforcement 07:33 - Wet-out reinforcement with epoxy 09:18 - Wrapping the carbon fibre around the foam core 11:22 - Machining the carbon sheet for the end plates 13:06 - Aluminium inserts for the end plates 14:56 - Cutting and bonding Nomex honeycomb 18:09 - Filling the edge of the honeycomb panel 18:36 - Assembling the finished wing For further information, including links to all products used in the tutorial, see the tutorial's project page on the Easy Composites website: Full Project Details USA ► EU ► UK & World ►