Proceeded with fabricating the lower cowl air seal. The lower cowl air seal is held in place by a strip of aluminum which is bent to match the curvature of the lower cowl air inlet. Bending the metal strip is pretty much just trial and more trial. Not only does the strip need to conform to the cowl curvature, but the bend is not perpendicular because the lower cowl air inlet matches the baffle ramp angle, which is not 90 degrees relative to the sides of the air inlet.
My air inlets are not exactly the same, due to fitting the upper and lower cowls, the inlets are roughly the same height, but the upper and lower cowl on the right and left side are not trimmed actually the same. It does not matter; these air seals are custom to the left or right side.
After bending the aluminum strips as needed, trimmed to allow for a nutplate to be installed for the AN8 screw that will hold the upper to the lower cowl where the two meet behind the spinner bulkhead.
Bonded the air seal material with Pliobond, the matched drilled for the AN 8 screws, three per side. The air seal is sandwiched between the aluminum strip and the underside of the lower cowl air inlet. The screws are attached with full metal nuts and washers.