October 6, 2008 - More Airbox 

Next step on the airbox was to make the carburator heat door mechanism.  The first step was to make a door out of aluminum sheet that conformed to the the airbox snout.  I started with a paper template, then switched to the aluminum sheet itself. 
 
After the door, I cut the supplied hinge to size and made a spacer.  All per the instructions.
 
I cut out the hole in the airbox top plate. 
 
I clecoed it all together.
 
Basically how the carb heat system works is this.  Normally the door is open, allowing air to come in through the cowl scoop, through the filter, to the carb.   When the carb heat knob is pulled, the door closes and blocks the air from coming in through the cowl scoop.  Instead, warmer cowl air is sucked through the hole in the airbox top plate, goes through the filter to the carburator. 
 
When carb heat is Off, the door is in the open position, as shown.  
 
I riveted the door and hinge mechanism to the top plate.
 
Notice the handle, which is what the carb heat control cable attaches to.
 
Cleco the top plate back in the fiberglass airbox.
 
The airbox all riveted together and bolted to the carburator.
 
View from the front, with the airbox door closed (Carb Heat On)
 
A view from the side.
 
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