Hello Tom, in your step 11 you state that you "Rough up the CF hatch cover in the areas where the mounts will attach." Why is this?
This is to ensure a solid bond to the carbon fiber. It is possible that a residue on the surface would inhibit proper bonding.
Also, you glue the mounts in place with thick CA or epoxy, clamp and allow to fully cure. Is this the servo mount or hatch cover mounts.
These are the plywood servo mounds that are glued to the carbon fiber hatch cover.
For the servo mounts, I take it that the fit has to be absolutely precise so that the servo/servo-mounts will 'just fit' inside the well. Do you leave the servo mounted for alignment purposes too while this is glued into place?
This is easily done by cutting the sheeting (in step 4) slightly larger than the cover. The resulting hole should be the width of the cover plus the thickness of the interior 'wall' pieces plus 1/32" (slight gap).
When gluing the 'walls' in place you could use the carbon fiber covers as a guide to ensure a correct fit. It would be a good idea to put two layers of masking tape around the carbon fiber cover (to provide the slight gap) and then positioning it while the 'walls' are curing.
-Tom