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For 5 years I worked at a facility that fabricated using various resins and materials. We used acrylic resin when laminating with carbon fiber. This was under a vacuum using PVA bags. Cutting out with a reciprocating saw and finish grinding and buffing edges smooth. Yes use a respirator and coveralls if you have them. Sometimes grinding it would spark, thats how hard it would get. Never had a problem with anything breaking. Watch your layup,( how you lay the carbon fiber on) and to strengthen it up, between layers of carbon, use a strip of felt or simular ( this soaks up resin and compresses easily).
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