The basic method I used was to cut the parts on my Shapoko CNC mill, although a steady hand and a jigsaw/drill can yield that same results, the sand them down to clean up the edges and ensure the holes were all clear.
Next I needed to paint them. The reason for this is a little know secret... once you spray paint any material black, it magically takes on all the properties of Carbon Fibre!! thats science kid!! :)
I use simple spraypaint and clear laquer, about 2 coats of each.
The rest is history but here are some build pics:
And Version 2:
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