In this picture, the interference between the alternator and the filtered airbox can be clearly seen. That's why the filtered airbox had to be trimmed.

And a second point of interference/proximity is the oil line going to cylinder head #2..

Manufacturing the air filter retainer/airbox mount to the baffling. Everything fits pretty tight around here.

A view of the situation from the side. Turned out we could barely have gotten by without trimming, but it doesn't hurt either. Plus fitting would have been more complicated.

The air filter retainer.

Modding the front right baffle for the cabin heat inlet and the prop oil line.

Everything is very 3-dimensional and it's hard to work based on a reference plane... Best is to test-fit / temporarily install the stuff on the engine.

Cowl gap. There will be a rubber overlap in this area. If the gap is too tight, it will be very hard to remove the bottom cowl for inspections etc...

Currently planning to take the alternator blast tube from the gap behind the prop oil line, so no extra hole will be required.

Air filter area and cowl gap from above.

In between, some reference pictures of the wheelpants for the design of a hangar mount. Since the wings are not on yet, the track width is narrower and the wheelpants slant outboard making the outer lower edge the closest to the ground.

Found a reference piece that exactly fits the gap.

slightly less than 1.5"

Weird perspective, but the outboard slant can clearly be seen.

Trimming the top of the baffles to fit the upper cowl was quite a feat. Tried to get everything more or less to the shape of the cowl and then started "shaving" the top off.

In some areas, quite a bit of material had to be removed.

Christian Keller, fellow RV-6A pilot and an engineer, stopped by to work on some paperwork requirements for the eventual Swiss registration.

As the main difference to the already flying RV's lies in the gear legs / configuration, we mostly looked at that.

Fortunately for us, we didn't have to start from scratch, as they already laid the groundwork on their RV-6A.

Continued with wrapping up the fiberglass work :-) (Paint preparation will be done at the painter's shop)

Closed off the airbox mods with several layers of fiberglass and epoxy.

The oil line recess.

And the "alternator" flat spot.

Turned out great for not using any jigs or moulds.

Also glued the intersection fairings to the wheelpants.

In some areas, the joint seemed a bit weak, so added some pop rivets to hold it tight.

Now only the alternate air inlet and the filter retainer are missing from the airbox.

The hole for the ring is cut.

This opening could be used for the engine to draw air from within the cowl in case the filter "freezes" due to ice or some foreign object like a bird blocks off the filter.

Installation instructions from Van's are usually quite good.

The opening "glued" to the airbox. Will be reinforced by pop rivets.

The panel received slight bending marks during processing. So we fillered them to be sanded smooth.

Baffling part after a lot of work, deburring, countersinking, riveting etc...

This area at the front looks rather straight forward, but due to the angles and close area behind the prop disk it was quite a pain.

The gaps between the rubber seal and the baffling metal will be closed with high temp silicone.