I am currently working on creating a hollow easy star frame for the ultimate UAV. Since it will be hollow, you can place large amounts of weight right at the CG without having to ballast out the plane. You can also attach a larger motor or have landing gear hardpoints built in. I can customize the design to meet anyones needs (pylon racing, ultra-light, see though, rough landings, etc).
All materials used are top quality aerospace grade. Only the highest grade Pro-Set epoxy is used and any carbon or fiberglass used is Aerospace grade, not commercial as you would normally get online.
(Price is based on materials used. Baseline model will be around $60)
I have produced a few of these out of fiberglass and will be happy to sell you a couple of halves as a diy kit. Just let me know if you want some pictures of what I have produced so far. I could do carbon or a mix/specific layup if you have something in mind that you want.
Right now I am working on creating a composite foam core bulkhead to insure correct allignment of the halves.
Any pictures would be nice.
The Easystar by specification is able to lift 900g extra without affecting the flight characteristics so I (a relative plane noob) cannot fly it. So a lighter version would only help the situation but by how much does your CF version beat the foam? If its not much I may go ahead with chopping my borked Easystar to create more streamlined Easystar. I can get carbon fibre as well as kevlar for £25 per sq.metre and with them laid cross weave rather than parallel and vacbagged it should be pretty sturdy.
I haven't weighed the aircraft yet but it will be heavier. You can try using a single layer of 1oz carbon to make the plane lighter but the plane wont be sturdy enough, and you'll find it will deform even under the lightest of flight loads at 900g. The main purpose of making a composite plane is to enlarge the payload bay. The stock plane can fly with more than 900g and even more if you use EZ glider wings.
If you plan on doing your own vacuum bagging around the stock foam EZ you will want to make sure you dont go above ~1psi or you'll crush the foam. With that in mind, you will need a very thin epoxy which will be hard to keep an ideal fiber volume ratio. If you want a set of EZ moulds I can help you with that as well.
Just buy some high performance glider wings to go with the CF fuse .
There is no point toiling over moulds for the EZ* wings when existing, more efficient, proven wings exist. Just my 2 pence ;]