Started the cold-air box/filtration system for the GT-4 car tonight. This is fairly complex as it consists of 3 separate components: The actual airbox that surrounds the carburetors, the air filter holder, and the transitional section that collects air from the front of the car and allows for air filter access.
Here's the first step in making the air filter holder.

 

 

 

 

Next step was to bend up the tapered cone section. Here it's temporarily secured with Clecos, it will be riveted and sealed later. I was going to TIG weld it, but quite frankly I'm not comfortable yet with welding thin-gauge aluminum. I made a cardboard template for the 4" ductwork, seen here taped to the aluminum cone.

 

 

 

 

 

Cone has been riveted and 4" duct fabricated…

 

 

 

 

 

Next step is the ductwork which collects the air from the front of the car. It attachs directly to the right headlight bucket.

 

 

 

 

Here the templates for the bottom and one side of the ductwork feeding the air filter have been fitted.

 

 

 

 

Starting to take shape finally....the top template in place

 

 

 

 

The final side template in place, and stainless steel over-latches are laid on the templates for configuring. I should be able to cut out and assemble all the sheet metal parts tomorrow night, if all goes well. I still need to make a screened inlet at the headlights, and some rigid plastic mini-ducts to direct air from the light openings to the air plenum just before the filter. Then the air box for the carburetors still needs to be templated and fabricated.

 

 

 

 

Finally got this off my workbench...

 

 

 

 

Ready for paint

 

 

 

 

 

Painted duct with rubber seals applied.

 

 

 

All ductwork fitted to headlight trim.

 

 

 

 

Front view.