Wayne, The duct construction was similar to the method Mark Langford used and describes on his website. http://home.hiwaay.net/~langford/corvair/plenum/index.html http://home.hiwaay.net/~langford/corvair/index.html This is a variation of the lost wax molding method. Mark bolts his ducts directly to the Corvair case. I bolt my homebuilt ducts to the commercial VW cooling shrouds. Bill Clapp has a custom set for his Corvair that he made from CNC carved molds. Check out pictures of the 2008 KR Gathering Here! http://www.krgathering.org/ Scroll down to picture #27. That is definitely professional artistry in motion. To make my ducts, I carved solid urethane foam (could use Styrofoam) to the exact shape needed, paint with micro to seal the foam and provide better surface for the tape to stick to. After the micro cures, wrap the foam plug with vinyl tape and duct tape. Vinyl tape will stretch around corners, but duct tape sticks better in the flat areas. Glass the plug and let cure. Epoxy will not bond to the tape. Rip out the foam and tape. You then have a fiberglass shell ready for final trim and finishing. I purchased the VW cooling shrouds from a VW performance shop for $23/set. These shrouds are made of steel. One could get carried away and use the steel shrouds as molds to make fiberglass cooling shrouds to save some weight. The steel shrouds do fit tight to the heads at the exhaust outlets. I thought that area would be too hot (1100 F) for fiberglass/epoxy shrouds, so I am staying with the VW steel shrouds for contact with the VW heads.
Sid Wood Tri-gear KR-2 N6242 Mechanicsville, MD,USA smw...@md.metrocast.net Very nice work Sid, did you make the ducts as well? They look very professional. Wayne and Kathy Tokarz
