Worked more on the interface between the air filter holder, baffles, and snorkel. This is definitely the least-documented and complicated part of the airplane so far.

1. I began prepping to do a bunch of fiberglass work to get the air filter holder channels to match to the sides of the snorkel. After looking at the gaps for a bit, I decided to try a bit of metalwork instead. I ended up bending some joggles into the z-channels, and lo and behold, this actually worked pretty well. I drilled pilot holes in the channels, then match-drilled the snorkel to them. Also drilled the aft z-channel to the snorkel, and filed the interface between the sides and aft channel a bit.

2. Began work on the front baffles. These are the ones that surround the starter flywheel and front of the engine case. I began with the right one, clecoing it in place using the stock Vans attach hole. The gap between the baffle and the case was over 1/2" in many places, so I began marking and nibbling off bits of the baffle, then filing the rough edges, reattaching it and checking it, over and over. After about 10-12 iterations, I got it pretty close. (The result of this movement was that the new attach hole for the baffle is over an inch away from from where Vans punched it. I think they should just NOT punch this hole, and let the builder determine where it should be.)

3. Marked the outboard side of the intake snorkel for the location of the alternate air door.

4. Filed and sanded the rough edges of the alternate air door. Countersunk the cable attach screw hole on the backside of the door.

5. Clecoed the door to the door fixture and marked where I wanted to make the bends.

6. Bent the door retainer flange over, then crimped the left edge of the flange to create a door stop. Filed the sharp corners of the flange.