The second wooden end piece is glued on.
With both wooden end pieces in place, final shaping of the plug can be done. In order to optimize flow, I make cross section area measurements, to try to get a smooth transition from the 6" diameter entry to the 4" diameter exit from the tube. When airflow enters a turn, it is beneficial to reduce the cross section area throughout the turn. This reduces the risk of airflow separation. That is one of the reasons I chose an airfilter with a big inlet flange.
December 25, 2008. The entire plug is covered with filler to create a nice surface.
January 01, 2009. After sanding the filler down, the plug is painted to show any surface imperfections and to give a better surface for the fiberglass molding.
January 03, 2009. The paint surface is sanded smooth and the plug is waxed several times and covered with release agent. The plug is now ready to be covered with fiberglass and polyester.
Next on the agenda is the sticky and smelly job of laying on fiberglass and polyester.
The air filter side of the intake tube is cleaned of surplus fiberglass.
January 04, 2009. To get a nice outer finish of the tube, the surface needs to be sanded smooth. This is easiest to do before the polyester is fully hardened.
First thing to do to get the plug out is to get the wooden end pieces out of the way. This is done by the means of sabre saw, chisel, and hammer.
The Divinycell foam is removed carefully to not damage the inner surface of the tube.
