How are you getting around the cell drainage, or are you using foam filled honeycomb? I'm just curious, I do pretty much everything with prepreg and don't do any street car parts anymore. I like to see cool methods of getting around problems though.

By the way, Nida-Core makes some perfect stuff for what you're doing, infusion cores and other cool things; I'm sure you've checked them out already..??

The reason that this stuff hasn't caught on is that the weight savings aren't there for the cost of the replacement parts, that and the fact that no one really wants composite parts that don't have the pretty "carbon look". If it were up to me, and the market was there, I'd make parts with a little carbon, some aramid, maybe some S-glass, and a cheap core, and make people paint them. Fuck unpainted carbon fenders, they're ugly. Hoods are kinda ugly too, but they don't break up the body lines nearly as bad as carbon fenders do from the side. I wouldn't worry about doing bumpers, they're not worthwhile unless you're using the flexible resin formulations, and they're plastic already so the weight savings aren't there as much.
I've always wanted to have a NC router table to make car specific bond-on fender flares for the rear and flared fenders for the front. Ship them with the right type of sandable adhesive, and they'd sell like hotcakes probably. Anything that isn't ricey and lets people use bigger wheels usually sells pretty well, and there isn't much of that on the market right now. Something like WRX sedan flares to put on WRX wagons would sell like mad, I've seen it done a few times and everyone wants it but nobody wants to pay for a one-off flare conversion. Enter the cheap composites guy.......

I'd love to have a long strand SMC setup in my garage, then you could whip out parts really cheap. You know, after you amortize the ridiculous cost of the equipment and the tooling..

Seriously though, if you have good tooling for resin infusion, you can pop some parts out for cheap if you keep the carbon content low or use cores to bulk them without much reinforcement cost. I just hate trimming stuff though, it's the biggest pain in the ass of the whole process.. No one has dropped a water jet or NC router in my lap though.