Mon Aug 3 20:09:27 2009 - I got the "good to glass" word from Don at AFP. So I spent some time on polishing the final shape. Namely, I smoothed out any bumps and glue risers. I also cleaned up the mating edges between the existing plenum and the future glass work. Ideally, I'll have a little lip on the inside that I'll be able to sand down to form a very nice transition. Also, I discovered that by using a Scotch-Bright pad, I can make very detailed improvements, compound curves, and blends with gentle rubs on this foam. I also did some research on mold release techniques and materials. I think what I'm going to do is apply long strips of Saran Wrap followed by either a very thin layer carnuba wax, Vaseline or even Pam (as in the spray on anti-stick stuff you use in the kitchen). I thought I read about the Pam option some time ago so I'm still researching it to make sure. When that is all done and ready to go, I'll be glassing this contraption in place.

Sun Aug 2 18:29:24 2009

Sat Aug 1 07:55:06 2009 - Don at Airflow Performance was kind enough to provide some great feedback on this plenum design. He recommended that the inside corner have a 'D' profile. So I did that this AM. He did not have any concerns about the outside corner. The horizontal mark at the end of snorkel marks the very edge of the AFP server inlet.

Thu Jul 30 19:51:17 2009 - Take two! It was obvious that during the 1st run, I used way to much "Great Stuff". What can I say, it's interesting stuff. Anyways, as it cured, it expanded. And as it expanded, it moved my plug about 1/2" from the inlet of the AFP servo. Live and learn. So I tore out the old "Great Stuff" to free the plug and started anew. This time with a little muscle to hold things in place and less "Great Stuff". I did discover that the "green stuff" does not dissolve in acetone nor does "Great Stuff" _after_ it cures.

Tue Jul 28 16:39:45 2009 - Final throws of shaping. I needed a way to fasten the foam to the snorkel so I bonded the two with "Great Stuff". When this sets, I'll hopefully be able to remove the snorkel, do any final shaping, apply some mold release then start laying up layers of fibreglass. I'll then dig out the foam and sand for a smooth inside finish. Anyways, that is the plan.

Tue Jul 28 15:54:39 2009 - After making a big mess, I decided to do a trial fit of the bottom cowling. It's hard to tell in the picture, but there is definitely contact between the foam and cowling. BTW, a hacksaw blade and strips of sandpaper work really well for shaping this stuff.

Mon Jul 27 17:53:08 2009 - I essentially just crammed the pieces into the snorkel and AFP to hold them in place. I also stuffed some paper towels into the AFP to keep all the dust out of the venturi innards and closed the butterfly valve.

Mon Jul 27 17:52:52 2009 - This is my first time doing this kind of stuff. My first attempt just ended up turning into a bad dream. I settled on this approach. BTW, I got this green stuff from Hobby Lobby. It's for putting artificial flowers in. Very light and very easy to work with. I also picked up a small bottle of glue that is made for Styrofoam so that I could glue the pieces together.

Mon Jul 27 16:43:53 2009 - Getting an idea of what have to work with with regards to cowling clearances.

Mon Jul 27 16:38:58 2009 - Hmmmm, I still have to make a pretty big swing towards the front. I ended up cutting about another 2.5" inches off from the snorkel.