Yesterday and today I kept on with ramping the internal edges of the armpit scoops with permagrit files and sandpaper.

It was surprising how look this took.

I knew I was done when both scoops were smooth and even to the touch. Ideally it would have a 7 degree or less slope. Mine is more abrupt because I will have diverters, dividers and baffles of some sort in there. I’m content to just have a good flow through the mouth to the scoop floor.

This intersection I knew would have to be addressed. The cowls were bent inwardly and no amount of heating or forcing into place seemed to work when I installed them.  Today I sat and stared for a while and now I know how to address it all. It will be wonderful, trust me.

After trimming both scoop edges I worked for the fit, 0.75″ from the sides and top. I just needed to hold them in position and then check and check again that we were good. Boxes, books, foam and tape, whatever I had lying around did the job. I made a .75″ spacer for the top that also helped.

Once I was happy, out came the hot glue all over the attaching edges. Soon I could remove the pile of stuff holding it in place.

Next up I checked my gaps.

Then checked again.

All was good and with the hot glue doing the holding, I drilled and installed a nest of clicos. Once this was done I took all the clicos off and detached the scoops from the cowl. I then removed all the hot glue and clicoed the scoops back on again. Then I rechecked the gaps and position. Yes we were still OK.

I again removed the clicos and scoops and this time, knowing my position was good, did a final surface prep. I mixed a batch of epoxy and added pure to both surfaces. Then came a batch of flox, I lined both surfaces and clicoed them together.

As the final step I drilled and added a few more clicos in places where glue squeezed out when I pressed the edges. A nice porcupine look ensued and after a clean up I headed home after another long day.