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It was a very similar circumstance, trying to snake an intake tube through a crowded engine bay for a one-off hybrid or something. It was on Discovery Channel like 20 years ago, I can't find any videos on YT of the same technique, but it always struck me as a very good idea. I can't believe that the guy in the show was the only one ever using that technique - especially given the ease of procuring and working with the materials in question.

Lost wax casting goes back at least a couple thousand years but it never occurred to me to try a composite part that way.

I added more spray foam tonight. Tomorrow I['ll give it a sand and see what I have.....it was looking a lot better though.

Here is a similar vent cover on a Michelotto 308. Also the airbox and hoses.

Thanks!

Maybe use an inverted cone filter?
That way you could just merge the side scoop into the filter opening and use whatever room you have behind the quarter panel to create a small airbox.
Something along the lines of the $0.5M Guntherwerks 400R:
http://www.speedhunters.com/2017/10/the-uber-911-gunther-werks-400r/#_presentation-350946

Have you toyed with the idea of using an inverted cone filter?
Take a 6" outlet filter and mount it to the body so that the inside of the filter now becomes intake.
That way, you only have to merge the side scoop to the filter.
And you could use whatever space you have inside the quarter panel as an airbox.

Something along the lines of the $0.5M Gunterwerks intake:
http://www.speedhunters.com/2017/10/the-uber-911-gunther-werks-400r/

Sorry I didn't see this pop in, I approved your account so you're good to go now.

Interesting thought for sure....I could look at it but I know I have a width issue as I get close to the vent so I'm not sure.

The duct is starting to look like it might be a duct some day. I've got a 4" round effective crosssection everywhere and not horrible looking turns.



I'm thinking I should remover the rubber adapter from the filter and attach the dust directly to save about 1" so more foam


Here is the 288 setup...possible

The people on other forums are trying very hard to get me to design something better....but right now I'm hooking up the basement hvac unit, hopefully back to car duct work tonight.

This might be a case where refinements can come later .I think you calculated a possible 30 hp degradation -which is really negligible .Clean air was your priority and current approach addresses this . Summer driving season will soon be here and it looks promising that this could be the year to enjoy the car .