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Building Integrity
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Date:  11-21-2017
Number of Hours:  7.00
Manual Reference:  Section 2
Brief Description:  Air filter tube re-design and Hatch lip

Today had many challenges that I couldn't foresee coming, but I feel I tackled them well. I started by trimming the air box hatch and sanding it to shape. By the way, the micro over wet glass was not a problem at all and saved me a cure cycle :). I went to install the air filter tube and wanted to make absolutely certain I installed it in the right position. This meant I had to temporarily mount the engine again and I'm glad I did. Total fail. The 90 degree elbow tube I made was contacting the throttle cable bracket and would have been a bad day had I found out when I went to hang the engine. This, however wasn't all that bad. I have been "hating" the idea of using CAT tubing for the intake as it is terrible for airflow the second you bend it even a little. I've wanted to use a smooth silicone coupler but knew it would take a more complex air filter tube to justify. Well, now I had justification. This time I went with green foam and metal tubes to ensure a perfect clamping surface for the coupler and filter. Green foam sucks, but it sands sooooo easily and did the job pretty well. I laid up 1 ply BID all over and will layup 2 more plies on the inside tomorrow after cure. This setup will now allow me to use a straight 60mm silicone adapter and I've found a way to make it simple to install when I go to hang the engine. Thumbs up for smooth airflow!
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Air box hatch trimmed in place

Air box hatch trimmed in place

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Final air box and intake tube test fit and fail!

Final air box and intake tube test fit and fail!

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New intake tube design

New intake tube design

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