After a heap of procrastination, I decided to have a go at a carbon fiber plenum...
CF has a number of attractive qualities that make it a nearly ideal candidate for manifold use. Aside from the obvious weight and thermal advantages, it has a nearly unlimited fatigue life. Fatigue resistance is one of my primary motivations as a boosted plenum is subject to significant stress. A well built CF plenum should survive many lifetimes. Add in nearly infinite shaping possibilities and an audible resonance that can't be duplicated by any other material.
Of course CF comes with its own drawbacks, mainly cost, manufacturing complexities, and a limited heat range.
Anyhow, the first step is to build a plug that mimics the final shape. A mold resembling the 'silhouette' was constructed, filled with 8lb expanding foam, and the plug extracted...
Next up, hand shaping...