Here you can see the gaping hole in the plenum, where I removed the previous duct used to connect to the old inlets. I'll get a couple pieces of foam and start carving. 

Time for a trial fit. I do believe this is going to work. Next task is making inlet ductong to the plenum. 

Two layers of glass applied to the foam. I should have shown a photo of the foam, before glassing, but I forgot to take it. 

Trial fit for placement! Looking good. 

Before I shape the outside, I think it is better to get started on mounting the inlets. First, I work on the cutouts. 

Now, the cowl can be re-mounted on the engine. This is where I will do the final carving and shaping. 

Again, using the Sawsall, I cut the foam directly over the existing split line, separating the cowl halves. 

A chalkline is snapped on the new foam, directly over the old split line. I determined that I want the center on the inlet rings 11.5" from the center of the crankshaft. 

Here, I am working on the foam, with a long sanding board, to make it even with the foward lip of the cowl. The inlet rings will be flush in this plane. 

Using my Milwaukee Sawsall, with a 12" saw blade, I started removing the stuff that didn't seem to belong. 

Plastic removed, ready for carving. 

I then wrapped plastic around the blocks then dumped in more two-part foam. 

First step to installing the new inlet rings: I prepared the cowl by sanding, then glued on a couple of blocks of foam using the two-part expanding foam from Wicks. 

My Never Ending Quest For Speed - The Affliction

Doing some careful evaluation flying, I have determined that I am now getting 174 kts at 5,500 feet, wide open throttle.

I have been using a spread sheet originally developed to use GPS to determine pitot-static error and it's located at the National Test Pilot's School web site. The idea is to fly in four different directions, at a constant IAS, and record your groundspeed. The spreadsheet removes the wind component and gives your true airspeed. It also computes the standard deviation (smaller is better).

From flight testing I did in the past, I can tell that my new wheelpants bought me 3 knots. Not a real lot, but three knots, nonetheless.

My next quest will be to install my new aluminum engine cowl inlet rings. These came from Sam James aircraftt, in Florida. Mr. James claimed I would get 4-5 mph improvement, so here goes...