After testing 3D printed side vents the results where hopeful. The printed parts passed the test, but they deform as a result of the heat. Getting the vents from Sonex takes a lot of time to get to Europe. Option 1 was to make a mold and lay-up fiberglass. This process would also take too long so back to the good old sheet-metal skills. I cheated a bit because I designed them in 3D CAD, printed out flat patterns and cut the parts out of a sheet 0.32 6061. A day handwork later and there finished. To compensate the taperered Legacy cowling I added deflectors. If anyone wants the flat patterns I can make them available.
Side-vent-Sheetmetal 3D.JPG (27.58 KiB) Viewed 1356 times
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