I decided that the deck is going to be a 8 layer carbon fiber 12X12 weave with a polystyrene foam core.

From to to bottom the layers will be C-C-C-F-C-F-C-F-C-C-C

After spending a few weeks tweaking the final assembly in solidworks and finalizing the deck shape I started making the mold.

With a couple friend at the architecture school and a few sheets of 3/4" MDF laminated a thick mold which was then handed over to the CNC router.

Hopefully by the end of the week I can start on the carbon fiber vaccuming operation.