I've cut plenty of carbon fibre. The process is
- Draw it on a CAD package (I use the free version of DraftIT).
- Print it out and stick it to the carbon using Prit Stick.
- Centre punch the holes using an optical centre punch
- Centre-drill the holes using a centre drill
- Drill the holes using a nice sharp drill. Use a slow feed to avoid tearing the carbon.
- Cut the edges using a dremel and normal cutting disks. You can do very good straight edges and curves if you take your time.
Bulkheads are more difficult; you'll need a mill and a lot of skill I reckon!
The main reason you don't see many scratch built TCs these days is that there's no way you'll make one better than the manufacturers can, with all of their facilities and top drivers giving input. The layouts and components on all the cars have evolved to an 'optimal' layout after 15 years of running.
For the project to be worth it you'd have to do something like a FWD or RWD, then you might be able to make something better than what you could buy.
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