Carbon Fibre Repairs: How We Repair Carbon Fibre Parts at Bodyshop Manchester

At Bodyshop Manchester, we’ve repaired every type of carbon component imaginable. From Bentley carbon side skirts to Ferrari carbon front splitters, Aston Martin spoilers and mirror caps, and Lamborghini diffusers.
Carbon fibre is one of the most desirable materials used on modern performance and luxury cars. It offers unmatched strength and lightness.
When it is damaged, it requires specialist skills, materials, and precision to repair properly.

In this article, we start with a short Q&A answering the most common questions about carbon fibre repairs. Then we explain the two main types of carbon fibre damage we repair and walk through the detailed process behind each one.

Q&A: Common Questions About Carbon Fibre Repairs

Can carbon fibre be repaired?

Yes. When carried out by specialists, carbon fibre can be repaired to its original strength and appearance.

There are two main types of repair. In some cases, the damage is limited to the resin layers that sit above the carbon weave. These parts are fully rebuildable using multiple coats of specialised resin which are built up carefully, avoiding any air gaps.

In other cases, the impact has gone through those resin layers and into the carbon weave itself, requiring a full structural rebuild.
Both types demand precision and extensive experience to achieve a genuine factory-level finish.

How much does it cost to repair carbon fibre?

The cost depends on the type and severity of the damage.

Surface resin repairs (where the carbon weave is intact) typically start around £250–£350. These involve rebuilding several layers of protective resin and applying a new UV-stable clear coat.

Structural repairs (where the weave is cracked or delaminated) can range from £700–£1,200+, depending on the part and manufacturer.

Even at the higher end, it is still far cheaper than replacement. Many OEM carbon fibre trims exceed £12,000 and are sometimes on backorder for months, making expert repair the faster and more cost-effective choice.

Is carbon fibre high maintenance?

No. Once rebuilt and refinished with UV-stable resin and lacquer, carbon fibre is extremely durable. The surface is effectively renewed, offering the same depth, protection, and clarity as when the part was first made.

What is the life expectancy of carbon fibre?

When repaired properly, carbon fibre can last the lifetime of the vehicle. The composite itself does not rust or corrode, and the newly applied resin layers protect it from UV exposure and everyday wear.

Understanding the Two Types of Carbon Fibre Repairs

Not all carbon fibre damage is the same. At Bodyshop Manchester, we classify repairs into two main types. This depends on whether the outer resin layer or the carbon weave itself has been affected.

1. Damage to the Resin Layer (Weave Intact)

This type of damage affects only the clear resin coating that protects and seals the carbon fibre. It does not affect the carbon itself.
It usually appears as scratches, stone chips, lacquer peeling, or cloudy patches on the surface. The carbon weave underneath remains fully intact. The damage is cosmetic.

2. Damage to the Carbon Weave (Cracked or Snapped Carbon)

Here, the impact has gone through the resin and into the carbon weave. This causes visible cracks, splits, or delamination.
This type of damage is structural because it affects the strength of the part. It is commonly seen on splitters, diffusers, side skirts, and spoilers after heavy contact or impact.

How We Repair Each Type of Carbon Fibre Damage

1. Resin-Only Damage (Weave Intact)

When only the resin and clear coat are affected, our goal is to restore the finish to factory clarity and gloss without disturbing the carbon weave beneath.

The process involves:

Careful removal of the carbon part
Each part is removed with precision to avoid causing further damage. Often, bumpers, diffusers, or side skirts must be removed first to safely detach the carbon section. This step requires specialist knowledge. Incorrect removal can easily cause cracks or stress marks.

Resin and clear coat removal
Once off the car, the damaged layers are carefully sanded back. This is the most delicate stage.
- If you sand too deep and touch the weave, the damage is permanent. The only fix is to replace the entire carbon section or even the full component.
- If you do not remove enough, the damage will still show beneath the new finish.
  Getting this right requires both experience and precision.

Rebuilding the resin layer
Multiple coats of specialised resin are applied by hand.
- Each layer must fully cure before the next one is applied.
- Any air trapped during the process will leave visible bubbles or marks.
- If this happens, the area has to be sanded back completely and the layering restarted.

Final clear coat application
Once the resin layers are built up and levelled, a high-gloss, UV-stable clear coat is applied to restore the depth and protection.
- For satin or matte OEM finishes, we use the correct clear coat to match the factory look.

Refitting and reassembly
After curing and polishing, the carbon component is refitted to the vehicle. Any trims or bumpers removed earlier are reinstalled. Every panel is aligned and secured to factory standards.

When carried out correctly, the result is a factory-quality finish with the original weave visible beneath a crystal-clear surface.

2. Carbon Weave Damage (Cracked or Snapped Carbon)

When the damage extends into the carbon weave, the part’s strength and structure must be rebuilt before refinishing.

The process follows similar early steps but includes reinforcement and reconstruction:

Careful removal of the carbon part
The component is removed with the same precision as before. Frequently, entire bumpers or diffusers need to come off to reach the part safely. Mishandling at this stage can make the damage worse. Proper methods and tools are essential.

Resin and clear coat removal
The damaged resin and clear coat are stripped back to expose the affected area.
- Sanding must be even and controlled to reveal the damaged weave without weakening the surrounding material.
- Over-sanding or excessive heat can cause delamination that renders the part unusable.

Rebuilding the carbon structure
- Real carbon fibre sheets are applied across the damaged area or the full trim using specialised resin systems.
- Each sheet is aligned with the original weave direction to restore both strength and appearance.
- In many cases, multiple layers are required to rebuild the part to its full thickness and resistance.
- Once complete, the component has a uniform carbon surface that matches OEM structure and look.

Building the resin layer
- Several coats of clear resin are applied and allowed to fully cure between layers.
- Air bubbles must be completely avoided. Even a small trapped pocket will show once polished.
- If air is trapped, the area must be sanded back and rebuilt to ensure a perfect surface.

Final clear coat application
The restored part is finished with a UV-resistant clear coat to bring back the gloss, depth, and protection of the original finish.
- For satin or matte carbon parts, we replicate the factory texture and sheen using the correct coating system.

Refitting and reassembly
Once the repair is complete, the part is refitted to the vehicle. Any panels or assemblies removed during disassembly are carefully reinstalled and aligned.

The result is a structurally restored and visually consistent carbon fibre component. It is identical in strength and finish to a new OEM part. It also

Why Choose Bodyshop Manchester for Carbon Fibre Repairs

At Bodyshop Manchester, we specialise in high-end vehicles and precision repairs.

Here you can find more information about our carbon fibre repairs Carbon Fibre Car Repair Manchester - Aftermarket & OEM Specialists

From Bentley and Ferrari to McLaren and Aston Martin, our technicians restore carbon components to OEM standards. This applies both structurally and visually.

Every carbon fibre repair we complete goes through a detailed process of assessment, restoration, refinishing, and quality control. The finish is indistinguishable from new.

Whether it is a chipped Bentley splitter, a cracked Ferrari diffuser, or an Aston Martin carbon spoiler, Bodyshop Manchester restores your carbon parts to perfection. You save time and money and avoid long OEM backorders.

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