The airbox is completed along with the extension of the air intake tube. I installed the airbox to the engine, fitted the cowl in place and measured the clearance through the hole. I then cut the airbox to allow a 2 1/4" inch clearance to the cowl and fitted and glued the 2 inch foam block into the cowl. With the cowl reinstalled I used a drill and bit, reaching through the intake hole and ‘machined’ out the foam to match the intake hole to airbox opening. A little sanding to clean up the surface and I laid in 6 layers of 2 oz. glass cloth. Once set, I sanded away an inch of the foam block on the inside of the cowl giving a nice smooth 1 inch lip of material with a ¼ inch gap to the airbox for the baffle fabric to capture. I added the fuel drain hose and baffle fabric to complete the assembly. Also along the way, I have been filling and sanding, day by day the intersection faring for the gear and tail as well as any other spot that I find needing a touch up. Since the process of filling and sanding is iterative with a day to cure in between, I like to always keep it moving. Time to move to a punch list to capture all of the little thing left to complete before paint and final assembly.
One more bit for the day. The interior guy came by with the carpet inserts and a final cash infusion to 100% complete the interior. All I can say is that it was expensive and is beautiful. How much you ask? I’m not saying other than materials alone (Mercedes leather etc.) was over $4K.
