You have trial fit the cowl & scoop in reference to the carb & where the FAB air cleaner will be? Don't guess positioning it or you might have clearance issues later.
-Cleko or solidly tape a spreader bar across the aft edge of the cowling to preserve the dimensional shape of the cowl in general.
-Mark a center line in the scoop and cowling to establish positioning while you work.
-don't trim the overlap yet. maintain about a 1" overlap with the scoop laying in place outside the cowling (laying inside compromises effective interior vertical clearances)
-drill a series of cleko holes all around the scoop & cleko in place.
-trial fit again, be sure you are happy with clearances before gooping things up.
-grind a taper to the external scoop surface edge, as well as roughing up the surface of the cowl in the gluing area. grind the mating surface where needed to get a snug fit
-with a flox slurry, glue & cleko together, let set
-later with flox slurry, smooth out exterior surface, than apply 2 layers of glass to join and smooth the exterior, final shaping can be done with micro balloon slurry, fill, prep for priming
-inside, use dremmel to trim back inside joint. also grind inner honey come back a bit to smoothly transition the inner surface followed with one or two layers of glass to seal it.
This is one way to do it, other ways will inevitably be suggested as well.
built a few RVs, rebuilt a few more, hot rodded more, & maintained/updated a big bunch more
Last edited by Ralph Inkster : 10-05-2021 at 12:29 PM.