---------------------------------------------------------- KIS-List Digest Archive --- Total Messages Posted Wed 07/31/13: 1 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 09:53 PM - How long does it take to build an throttle body airbox? (Robert Reed) ________________________________ Message 1 _____________________________________ Time: 09:53:56 PM PST US From: Robert Reed Subject: KIS-List: How long does it take to build an throttle body airbox? Answer: FOREVER and then some.=0AI never noticed that the throttle body on my aircraft was NOT Centered under the engine and was a full two inches tal ler than a normal throttle body. As a result the NACA inlet that I carefull y centered in the cowling was NOT going to work. I found an air box on EBAY for the Lycoming 360 engine with alternate air and filter which was as clo se as I was going to find without a total custom fabrication. I paid a gran d total of $45 dollars including shipping. Not a bad price.=0AThe problem w as that it stuck down way too low and was too far to the pilot side to fit with the NACA inlet. The top of the filter unit was to high as well. I had looked at numerous other options and all of them was going to require a red esign of the cowling so the fun begins. First I cut out a full section of t he lower cowling for a removable panel. The throttle body/air box was offse t a full 1 1/2 inches. First thought was to just reshape int inlet area and connect to the air box. I knew that I was going to have to fabricate some sort of baffle to connect to the cowling air scoop so I started trying to f abricate an attachment. =0AI have also been trying to find a good place for the air inlet for a hose connection to the heat muff for cabin heat. Then came the little light bulb of an idea. Why not use that extra 1 1/2 inches to fabricate a simple little box for the air outlet? Simple is obviously a relative term and after 2 1/2 days of 100 degree heat I have just about fin ished that simple little box. The baffle opening to the air box will be sha ped to slide in the air scoop outlet and form a seal without having to use a screw connection. I will complete the air box inlet and the shape the air scoop to fit snug.=0AWhat made the "simple" little box take so long? First was trying to fabricate it around the existing air box and filter with a b affle seal that could be removed for access to the filter. It needed to att ach to the existing attachment for the filter and keep the seal. Finally, t he whole thing was built with just flat stock and off the shelf aluminum st ock using hand tools without a metal brake.=0ANO PROBLEM.Right? =0AThe attached photos show the purchased air box attached to the throttle body.The second photo shows the butchering of the inlet to get the lower co wling on.The next photo shows the lower panel removed with the cowling inst alled.You can easily see the offset and how low the filter sets.The last tw o photos show the cabin heat source box attachment and the last photo shows the baffle material in place and ready to be cut, riveted and trimmed.The challenge was keeping everything tight for a good seal while making it remo vable for access to the filter.Looks like it=99s going to work but st ill have a couple of more days work to fit the cowling and fabricate the ai r scoop.=0AI will put up more photos of the completion.If I ever get it com plete!!!!=0ABob Reed ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message kis-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/KIS-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/kis-list Browse Digests http://www.matronics.com/digest/kis-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.