Mon Jul 27 16:36:33 2009 - First cut complete. I also removed the Plane Power alternator to make room and to keep dust out of it.
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Mon Jul 27 16:25:58 2009 - Ok, so here is what I have to work with. The black vertical line represents where the front of the AFP servo would be if it were mounted to the sump. I have a lot of trimming to do.
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Sun Jul 26 14:57:27 2009 - Done! - At least this end of the intake system. I've a good seal all the way around and it is surprisingly sturdy as is.
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Sun Jul 26 13:19:09 2009 - I'll need to glass in a relief here for this oil return line.
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Sun Jul 26 13:18:52 2009 - Test fit and so far things are looking promising.
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Sun Jul 26 11:33:18 2009 - Epoxied and riveted the mounting flanges. Nut plates will eventually be riveted to these flanges.
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Sat Jul 25 15:18:00 2009 - Since the inlet floor baffle has a compound curve, I trimmed the fiberglass airbox to better conform. You can see that the rear-left corner is slightly raised.
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Sat Jul 25 15:15:05 2009 - Long ago I had some Z-Channel custom made to extend the instrument panel. It so happens that it was about 6" too wide and I need some .060" 90 with a nice big flange. So I cut off the excess length, cut off one of the flanges, now I've got a nice sturdy 90 angle. Best of all, it allowed me to use the old rivet holes on the outboard baffle. Now it looks like it was originally planned that way.
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Sat Jul 25 13:11:22 2009 - I sure get nervous when I start cutting big holes into aluminium. I purposely cut the hole undersized then cut out 1/8" strips to fine tune the fit. The outboard side has a little more overhang than needed but I wanted to preserve edge distance for the rivets. All this commotion is caused by the fact that I riveted up this portion of the baffles not realising that the FI airbox was going to require some extensive modifications in this area.
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Fri Jul 24 19:38:21 2009 - Definitely some initial fit problems and that is Ok. From this picture, I ended up moving the entire assembly outboard. If you look closely, you'll see one of the shop heads that attaches the inlet floor to the outboard side baffle. I positioned this shop head in the very forward-outboard corner of the K&N filter. Things just seemed to fit best around here.
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