Fitting the air duct took many iterations of checking the fit, then trim/sand, then check the fit again. I had to trim down the aft outer flange of the air duct quite a bit to get it high enough to put the opening in line with the radiator. I used my phone to take a movie while reaching my hand up into the air duct to check the opening alignment. When I thought I got it close enough I drilled a few holes through the cowling…as much as it pains me to do it. I still think there will be some more adjustments, but this will help keep it close. I noticed the air duct flexes the lower cowl a little close to the spinner, so it will be interesting to see how it all fits when I get the upper cowl back on. One thing that helped with aligning the duct was to take the air duct interface by itself and mark the location on tape around the radiator seal flange. I traced the outline so I could see how I needed to move the duct to meet back up with the outline. You can see the outline in picture 2, although the angle of the photo makes it look like it’s not lined up, when it does line up fairly well.
