The original intake scoop which form part of the jet unit intake was missing so a new one had to be built from scratch. This was done by cutting a suitably sized steel base plate, and then building up the shape of the scoop with expanding foam filler. The foam was then cut to the required shape and glassed over with several layers of glass fibre.
Expanding foam used to form rough shape of scoop
Mold removed
Cutting leading edges to shape
Shaping the foam
Adding fibrefiller to smooth out the foam
Smoothing out the filler. Starting to take shape
Final stages of fairing
First layer of glass
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