Yes, I realize this looks pretty hillbilly, but I had to start somewhere. Most important in my world was protecting my shiny new engine from epoxy drips. The duct tape gave me the basic shape.

I wetted out a couple of layers of 6oz. cloth and then draped them over the duct tape. Keep in mind that all I'm doing is giving myself a base upon which to layer foam, clay and Bondo. No part of this mess remained on the aircraft in the end!

OK. Aircraft restoration for those with ADHD. (Attention Deficit Hyperactivity Disorder)... While waiting for the resin to cure, I decided to remove this little bracket. The story I got from the original builder is that this fitting was machined by Ib Hansen of Sonerai fame from the Denver area. It was originally used to bypass oil to and return oil from an oil cooler. My theory is that I won't need an oil cooler because I'm doing a better job on the baffling. I'll keep this fitting handy in the event I eventually need to install an oil cooler. For now, it's going away...

I found the proper seal in my ever-growing pile of extra parts and pieces. I also discovered that the prior owner/builder included the original part. Wooo, hoooo! My rattle can high temp spray paint matches the powder coating on the engine case pretty well, don't you think?

I guess I don't have any pictures of the steps between the duct tape and the final part. I used clay (mostly) to build up the base layers of wetted out cloth over the duct tape. I brushed PVA mold release on the clay and then layed on 4-5 layers of 6oz. cloth. This part still has the fuzzy edges so it needs to be trimmed.

And here's the basic part trimmed closer to its final shape. Keep in mind that I was just trying to get the basic shape at this point. I still need to glass in the portion that runs between the cylinders and the actual cowling intake.