Here is one half which is made of 14 layers of 400gsm unidirectional carbon and a top layer of red 2x2 twill.
Need to make the other half (another 10 layers) and bond them together.


My second composite mold which is an E46 M3 reinforcement plate came out pretty good. It was a lot trickier than the E90 plate. More sharp edges which makes it difficult to layup. Gonna need some gel coat repairs and had some PVA issues (the dark spots). Switching to a chemical release which is much easier.
Need to repair wet sand and polish the mold. Let sit for a week and then I can make a carbon plate. Should be 3 lbs, less than 1/2 the weight and should be about 2x stiffer than the OE part (rough calculation, could be wrong).
I think this part will be the first of its kind. Not sure anyone would spend the time to make a carbon part that no one will ever see.
There is some risk.
First, I wonder how the bolts and threaded body inserts will hold up. Much of the load will be transmitted to the bolts and threads. A little worried about the bolts which thread into the aluminum FCAB housings.
Second potential issue is durability and impact resistant.
Third is galvanic corrosion. I will bond titanium washers to the bolt holes which should take care of any issues

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