October 8, 2008 - Air Scoop

Next item on the agenda was to extend the air scoop opening so that it matches up close to the airbox inlet. 

The instructions have you glue the below sanding block in place, hollow it out, and fiberglass the inside of it.  Then chip away whats left of the block. 

So here I am trying to figure out how to fit the rectangular sanding block in there. 

 
Looks like I'm going to have to trim the block to get it up against the scoop inlet.
 
The good news is that the block trims very easily.  I used a box-cutter knife to trim. 
 
You can see how the block is wedged tight against the scoop inlet.
 
I used clear RTV to "glue" the block in place.
 
I used my Avery deburring tool to "drill" holes through the block.
 
 
Then I used a course hole file to widen the opening to the same diameter as the scoop inlet.
 
Cutting the fiberglass cloth that will be applied to the scoop.
 
I exposed the glass cloth inside the block.  Of course it won't stay flat without some help.  The instructions suggested blowing up a balloon inside the block to hold the cloth tight. 
 
Generally it worked pretty well. 
 
Here I'm in the process of trimming off the fiberglass edges and sanding everything smooth.
 

Havn't trimmed this side yet. 

I will probably need a follow-up session of fiberglassing to get the "tube" the way I want it.
 
 
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