Sweet idea on the undersuit.
Back on the Carbon Fiber topic, carbon fiber doesn't run $100/square yard. At
Fibre Glast.com it will run you $59.99 for a 36" x 50" piece. However, unless you're using the 12K Harness Triaxial Weave material (Double the price!) you will need to laminate at least 6 layers for your armor to hold up to impact and most likely line the insides of the parts with 6KH Kevlar for maximum impact and ballistics protection. Also, you will need to get the bake under vacuum epoxy resin to use for lamination as polyester resin will not hold up at all to any kind of impact.
You will also need to vacuuform molds out of thicker plastic over your fiberglass parts in order to create molds to laminate the carbon fiber into so that you can get perfect parts when you go to vacuum bag them.
In short, it is possible and very practical to make your armor out of carbon fiber. It's just up in the $5000-$7000 range of building parts.
Alternatively: You can use aluminized [black] fiberglass (
Fibre Glast.com) that will give you the same look as 3K Twill Weave Carbon Fiber but at a much more reasonable price ($20/yard). It will basically be a fiberglass part that looks like carbon fiber when you're finished. Just vacuuform the mold, add vaseline for a release, spread a layer of resin on the inside, place the black fiberglass over the resin, paint another layer of resin on, and then use something like a clear painter's drop cloth to put over the top and vacuum the plastic down over the resin & fabric. This will give you a faux Carbon Fiber shell to then go over the inside and resin/fiberglass normally.
