Work continues on the airbox and I've had a couple of quotes for aluminium cut to size for a backplate and sealing ring, £40 + VAT and delivery for the pair, so I doubt it's worth trying to make one myself or buying and cutting a ITG one.
So the plan at the moment is to have the aluminium backplate and ring supplied, that's the yellow and the blue parts in the cad image below, and then form the rest of the airbox from fibreglass or carbon fibre.
I'm not sure at this stage whether to bond the sealing ring into the airbox or just have it on top to spread the weight.
The best quote I had for the backplate was £30 plus delivery and VAT from LaserMaster, so I confirmed the drawing and paid them yesterday morning and this morning the parts were delivered.
Next job is to finish off the grommets, the ITG ones had a very large OD, meaning they would overlap, so instead I have managed to find some wiring grommets, though these need slight alteration to fit.
I was pleasantly surprised with the service after another company, who quoted £40+ also would only start work after the cheque cleared, LaserMaster took payment over the phone.
The first trial fit looks OK, I'm going to have to fettle one or two of the holes though to make it fit better (my measuring inaccuracies) and then add a mounting point or two back to the inlets to hold it steady.
Then I thought I'd make a start on the airbox, first step was to find something I could mould into the shape of the airbox to lay the fibreglass onto. First thought was to use that green flower arranging foam, oasis, but I couldn't find a large enough piece locally, so I got creative with a cardboard box, some plastic and a can of expanding foam to make this:
Which was roughed out to this, using a jack saw and rasp:
Before adding radii, covering in tape and trial fitting one of the air inlet pipes, which will be moulded in with the fibreglass:
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