Spent about 6 hours sanding the the front portion of the ductwork (and ground down several of my fingernails to a shocking degree). The front section is being handled differently than last week’s center section; this “plug” being a permanent part of the finished product so it won’t be coated with wax… probably. With the epoxy having cured from last week, the “side pockets” were dug out down to the inside surface of the epoxy. This allows the cloth to extend around the lip and into the inlet scoop, bonding to the outer skin and forming a sandwich, which is far stiffer than a single layer. The foam I’m using isn’t technically structural (it’s very weak in compression) but it doesn’t need to be in this application.
A pattern was made and a layer of fiberglass draped over to see where the seam should go since the assembly needs two pieces due to the inlet. That’s as far as I got today because laying it up is an operation that once it’s started it shouldn’t be stopped. Also, with the pattern defined I can see whether there’s enough cloth and epoxy; running out of either part way through would trouble.
I included a couple pictures of the rear section and the air cleaner because I’m wondering how much the air coming through the duct gets heated as it passes through the intercooler. It’s sort of tempting to have the air cleaner draw from that same duct since it’s right there. The interesting thing is that under full throttle, the engine sucks in so much air that it would actually increase the cooling air flow through the intercooler. It would be warmer than ambient by “some” amount, but that might be made up for by pulling more air through. Something to think about.
During our errands we saw an old and new Mustang nose to nose. Seeing them side by side, the new one look both bulky and large compared to the first generation. As good as the new ones are, the original has a timeless shape.
Speaking of Mustangs, I happened across this video of a trackday held yesterday at Willow Springs. The reason I mention it was that in watching all the cars heading out onto the track, it was interesting how much has changed since my brother and I did this back in the 1980s. Back then, probably 90% of the drivers drove older cars which they worked on themselves. Watching the video, it’s pretty clear that percentage is more than reversed; probably less than 5% do their own work (Mustang owner included). Of course, what is there to do? Go buy a Ferrari, Porsche, BMW, Lotus, or Corvette, and you’re good to go. I can’t help feeling that we’re losing our familiarity with things mechanical. That’s driven home where if one of these cars has trouble, the owner just pushes it into the enclosed trailer and drops it off at the shop Monday morning. I guess it’s neither good nor bad, it’s simply the new normal.