To answer a few of your questions:
I'm assuming you make carbon shafts at work? Yes.
First off, how much is this going to cost to have you "whip up" a custom one? This was supposed to be a DIY project, not a full production product :)
A LOT ... actually if we make this simple and just do a round shape it won't cost a thing as I already have lots of tooling in the mentioned diameters. Thinking you just want a few tubes to play with, not planning on selling these ?? Going oval or with a bend can be done BUT now you are talking additional cost and I wouldn't even suggest we go down that path unless you are thinking about making and selling thousands of these.
Secondly, what type of capabilities do you have? Can you make any shape out of carbon? Or just round shafts? Can you make a shaft with a bend in it? How about a oval tube with a bend in it?
The carbon shaft I have been looking at getting (Macqc.com) has in ID of .75" and and OD of .82". However, if you can make any size, I will change that.
I have standard size tooling available without having to buy anything. .75", .6875", .8125", 1.00" etc.
OD you are looking for doesn't matter. I can make any outside diameter as that is based on the number of wraps of the carbon. 0.035" wall thickness sounds good to start with. I need to look at the head insertion depth and will look at adding some fiber orientated 90 degrees to add some hoop strength.
In one of your first posts on this thread you mentioned the carbon being 20% stronger. The numbers passed on to me from macqc show the carbon being several times stronger then aluminum (ie. 295 ksi tensile)...can you achieve these types of numbers? In my design, the shaft is not the weak part in any of the tests, so really, if we wanted to push it, we could thin the wall even more (if that is possible). YES
I posted the link to the UIAA specs in an above post. Take a look at it and you will see what loading the shaft has to be able to withstand. I think the worst one is the shaft, fixed on one end, and a load of 550lbs or so @ 500mm on the other end. Let me know.
As soon as I get a break from work I will check out the site and see what kind of loading the shaft will need to take.
This could get really good!