Step 8: Upper inlet rings and tubing
(You could do the upper rings at the same time you do the lower rings and layups)
With the cowl pinned/screwed together, enlarge the cooling inlet holes just enough for the aluminum inlet rings to fit. Sand and clean the areas on the inside of the cowl where your mixture is going to go to trap the rings.
Put several coats of wax/mold release on the aluminum rings. Use some molding clay to fill the 'notch' in the aluminum ring in the area where the top/bottom cowl split lines are. You don't want any epoxy in this area.
Position the cowl on it's nose and position the rings in place making sure they are flush with the front surface. Use more modeling clay to block off any areas that you don't want epoxy flowing to. The idea here is create a couple of rings of epoxy to capture the aluminum rings.
Create a mixer of epoxy/micro/flox. Leave it thin enough that it will flow into the groove of the ring. Even having it flow out the bottom around the ring is good since it will fill any gaps and can just be sanded down later. Pour just enough mixture to fill the groove and come up to the edge. You don't want to put too much covering the area where the inlet hose connects to the ring. Let it cure for a good 24 hours.
Split the cowl halves and cleanup as necessary! (We are almost done!)
Screw the plenum in position and install the lower cowl. Cut the wetsuit material provided with the kit in half so you have two equal pieces. Wrap each pieces around the ring and the plenum and mark a line for trimming. It will need to be trimmed on both edges. For the lengthwise cut, make it as clean a trim as possible.
Remove. Spread a table with newspapers and pull out the glue provided. Massage the tube a little but not so much that you split it open! Following the instructions on the tube, spread the glue on each edge of the material and let it dry for 5 minutes, then do a second coat and let it dry for 10 minutes. Then butt the edges of the material together carefully. The glue is sticky and you get once chance at this. Let the glue setup overnight.
Now you can take your 6" hose clamps and clamp the 'tube' to the plenum and aluminum ring!
With the cowl pinned/screwed together, enlarge the cooling inlet holes just enough for the aluminum inlet rings to fit. Sand and clean the areas on the inside of the cowl where your mixture is going to go to trap the rings.
Put several coats of wax/mold release on the aluminum rings. Use some molding clay to fill the 'notch' in the aluminum ring in the area where the top/bottom cowl split lines are. You don't want any epoxy in this area.
Position the cowl on it's nose and position the rings in place making sure they are flush with the front surface. Use more modeling clay to block off any areas that you don't want epoxy flowing to. The idea here is create a couple of rings of epoxy to capture the aluminum rings.
Create a mixer of epoxy/micro/flox. Leave it thin enough that it will flow into the groove of the ring. Even having it flow out the bottom around the ring is good since it will fill any gaps and can just be sanded down later. Pour just enough mixture to fill the groove and come up to the edge. You don't want to put too much covering the area where the inlet hose connects to the ring. Let it cure for a good 24 hours.
Split the cowl halves and cleanup as necessary! (We are almost done!)
Screw the plenum in position and install the lower cowl. Cut the wetsuit material provided with the kit in half so you have two equal pieces. Wrap each pieces around the ring and the plenum and mark a line for trimming. It will need to be trimmed on both edges. For the lengthwise cut, make it as clean a trim as possible.
Remove. Spread a table with newspapers and pull out the glue provided. Massage the tube a little but not so much that you split it open! Following the instructions on the tube, spread the glue on each edge of the material and let it dry for 5 minutes, then do a second coat and let it dry for 10 minutes. Then butt the edges of the material together carefully. The glue is sticky and you get once chance at this. Let the glue setup overnight.
Now you can take your 6" hose clamps and clamp the 'tube' to the plenum and aluminum ring!
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