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Another method to make your air intake box is to do as I did. When I built
my 235, the factory didn't have their pre-made box available so there was
nothing to do but make my own.

I went to the local hobby shop and purchased a couple of balsa blocks large
enough to carve the proper shape. Carving your own will allow you to control
the shape to fit your requirements. The balsa mold is sturdy enough to make
trial fits so you can get an exact fit.

Once that was done, the shape was sanded smooth (easy to do with balsa) and
carefully covered with good ol' duct tape as a release agent. Since the 235
air box is made in two pieces (top half and bottom half) I layed up several
layers of FG for the bottom and, after it cured, I removed that half then
added several layers of tape (so the top half would fit over the bottom) and
layed up the top half.

After a bit of trimming of the edges, the two parts fit together nicely with
about a half inch overlap and they were then attached to each other with
ordinary anchor nuts (nut plates). A bit of red silastic around the seam to
assure a seal and it's been working well for nearly 700 hours.

The heated air intake for carb heat was layed up separately and attached to
the finished air box.

Dan Schaefer

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Please send your photos and drawings to marvkaye@olsusa.com.
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