Cold in the garage and I didn't feel great, so I didn't get as much done this weekend as I wanted. I did drill all the holes in the left inlet ramp, side baffle, and air filter parts up to final size. Then I deburred all the parts, and installed nutplates on the brackets that attach the inlet duct to the baffle:
Another trial fitting. Note the two countersunk 4-40 screws at the outboard forward corner – I found that these are necessary to keep everything together.
I bent a flange on the bottom of the left baffle piece, to add a bit of extra stiffness, then riveted the various angle brackets to it.
Here's what it all looks like when it's screwed together, minus the air filter of course. This is way overbuilt (you could probably use it as a tow hitch!) but at least everything fits and it's not going to come apart. When it warms up a bit, I'll glue and then rivet the bracket thingies to the air duct, and patch the holes I had to grind in it to make it fit.
Next chore: The right inlet ramp and baffle! Luckily there's no air filter on that side, so hopefully it will be easier.