So, ploughing on..
Seeing as I'd taken the easy route and moulded the opening for where the cooler would sit as a rectangle I was faced with the fact that there would be 2 large gaps at each end. Solved this with a couple of small aluminium seals....(the 2 redish bits on either side of the matrix..can you guess where I cut them from
When installed they look like this...
when installed properly, I will use a bit of sealant around the edges so they are 100% airtight. This ensures that ALL the collected air will pass through the cooler and not around it
Did a little bit of cutting on one side to allow the cooler to sit a tad lower in the duct..
Just needs painted and a small bit of sanding down of the round inlet as I seem to have gone a bit thicker than I would have liked....My 76mm hose no longer fits over the inlet so a bit of thinning out is needed.
Nearly there though.....