Completed air filter box. Riveted on filter retainers and installed alternate air door. Trimmed bottom cowl inlet to provide 1/4" clearance and sanded.
Worked on top of baffles. Have to trim some to get the paper clip trick to work, some of my preliminary clearances were less than wire thickness. Marked the baffles for a 1/4" clearance and trimmed.
Tried puttting a curve in a piece of hinge material that fits the rear baffle. It can be done, but you can't go more that about 5 eyes before having to cut the shrunk hinge because the gap between the eyes oens up and the 90 degree hinge does not fit. It will work, however, so the answer is a carbon fiber plenum with hinges on the sides and back. The front will be a few nutplates. Ordered material from ACS.
