Composite fabrication method and tooling to improve part consolidation

A tooling concept for forming a composite part having a cavity therein and formed of composite material, comprising:

• a plurality of rigid tools that are assembled together to form the tooling concept, the plurality of tools including a base tool having opposite side edges, opposing side tools extending along the base tool opposite side edges, respectively, each of the side tools having an inner surface facing the inner surface of the other of the side tools, a first side tool mount fastened to one of the side tools at the inner surface thereof and fastened to the base tool for positioning said one side tool relative to the base tool, a second side tool mount fastened to the inner surface of the other of the side tools and fastened to the base tool for positioning said other of the side tools relative to the base tool, the side tools having exterior surfaces remote from each other and being positioned with their inner surfaces spaced apart, the interior of the tooling concept between the side tool mounts being open;
• the tooling concept being configured so that composite material for forming the composite part can be laid up around the tooling concept so that the tooling concept is within the cavity of the eventually-formed composite part;
• and
• the plurality of rigid tools being configured so that they can be disassembled and removed through an opening of the cavity after formation of the composite part by unfastening the side tool mounts from the base mount and removing the side tool mounts, side tools and the base tool through the opening in the cavity.