Again, I skipped a lot of steps - sorry. To make the snouts I simply attached a block of foam onto the existing plenum with 5 min. epoxy. Then I carved to shape. Next, I laid up four layers of BID. To keep the BID from permanantly attaching to the foam and creating a lot of hard micro bumps, I first used a fairly dry micro on the foam - but with no hardener. After the epoxy fully cured I poured about 1/2 cup of MEK onto the foam. It melted the foam very well and I got a fairly smooth internal surface because I used the micro without hardener.