Vacuum bagging is no problem, we do it on almost every part we make.
I don't think i'm too worried about fire personally. The general layout
is important.
The spacers need to be inserted prior to thermal cure. The mold would
need to have
the sides needed for a motor mount built in. This part might be best
done male-molded.
The vacuum bagging would give a super finish anyway.
Bill

Good idea on the built in motor mount. We considered this
a long time ago sand cast in aluminum but the heavy weight was
discouraging.

Carbon fiber would be another matter entirely.
Here are a few old dwgs. It would have to be redesigned
for carbon fiber. I'll work on it.

-- Paul Lamar ...No rotor no motor.

Paul,
 The motor mounts need not be actually made from the mold. The flat
sides George did for the aluminum BH would work too. That said if the
shape could be kept somewhat simple it would be lightest to mold them
in. A thin rib is difficult to set up in the mold of course. A fluted
shape is better while still being removable.
Bill

Bill,
I was just thinking about stiffeners and how they might be incorporated
integral to the design. I don't think the stiffeners need be high
considering the stiffness of the carbon.Perhaps like the Mazda aluminium
housing with low wide ridge, (is that what you mean by fluted shape ?)-
perhaps even foam filled to keep the weight down if you wanted a smooth
inside wall. Any number of ways of doing it.
George ( down under)



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