I reinforced the underside of the lower intake lips with 200gsm CF and filled some slight gaps and holes in the upper side with epoxy & Aerosil. When this sets, I'll trim it all back and finish the upper cowl ready to set it into a bed of epoxy & Aerosil with the two halves joined. That should form a perfect match fit, minimise airflow between the lower and upper halves and ensure the fit doesn't change when the cowl gets hot in service (after the outer surface profiles are smoothed to match and painted).
