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The picture below is of the horn material I make based upon the SuperGee II Plans and e-mails from Mark Drela. If they work it's due to Mark's excellent design, if they don't I probably fouled up somewhere. Still easier to try these than go to the hassle of making your own. See Techniques for more details.

This material is three layers of sheared 93gsm Carbon Cloth with an aerospace quality Epoxy Resin (OK I chose it because it has a 90 Minute pot life, but it's still good stuff). The larger piece is a pre-production sample but it's included as it has two wire pins and a horn drawn on it, illustrating the technique.

This close up shows the paper side (This is to make it easier to draw your horn shape, etc. This peels off at the end) and a couple of short pins to illustrate the pre-formed hole positions. The holes are within (or close to) the circles printed and the arrow shows the major cloth direction (i.e. make the horn in this direction).