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Which leaves me with these parts I have now joined the upper drum to the inlet with more resin/matting I hope people are finding this interesting, its been a learning curve for me with the fibreglassing. I'll have more pics to post in a few days. Mark

Next job was the transition from the inlet to the round pipe. Started by making a jig to hold it. Next was the flat parts pre made Then with bare cardboard and lots of masking tape, stick in the curved sections and apply resin and matting in layers View down the inside I did have...

Time to introduce a bit of metal into the mix, 4 inch spital ducting The first piece is to form the outlet to the collection drum. First the bottom of the cone is marked Then cut off with the grinder Fitted and grip filled to the inside Eventually it was glassed over I am...

Test fit, very happy Mark

Next the nervous bit, cutting it out. The beauty of fibreglass is it can be patched, but still very nervous about getting it right first time. I drilled out a row of holes to get the hacksaw in. I got about an inch and a half before the hacksaw blade broke I then got about another inch...

Next job was to try and work out where to make the cut out in the upper drum to fit it in. It fits at an angle. The angle needs to be such that a line taken from the top of the inlet meets the bottom of the inlet after one full turn, and will be the path of the air ramp. My mate whos a...

I then started to build the air intake. Ideally I needed some thin flat plastic. But I didn't have any so I used some more cardboard :) I the built up several layers of resin and matting on it When done I hacksawed it down to the sizes I needed Then stuck it together with masking tape...

To pick up the build... Once the thin coat of resin was dry, the cone and cylinder had a nice "plastic" ring to them when tapped. It was then a process of building up layers of resin and chopped strand mat. I started with a layer of 100g to add a bit of strength before a started pressing...

Not sure about how well it will work with a router, everything I read suggests not that great but I don't know Venting outside is ok in summer but in winter all the warm air is blown outside to be replaced by cold air Mark

With regards to the blower, I'm still undecided. When I first started thinking about this I was going to get hold of a multi motor Camvac with the hope I'd get some suction off power tools with a smaller hose as well as 4 inch on the machines. I'm now leaning towards the normal HVLP blower...

So here's where it starts to get strengthened and made air tight. The outsides of both bits had polyester resin brushed on. I was quite concerned that this would wet the card too much and possibly make it soggy, so I made sure it was a very thin layer. However I had nothing to worry about as...

The cone was then secured in the right position with more masking tape Mark

Then had to try and make sure it was sitting evenly in the former and not off to one side, which I had to do very carefully by eye Which means I could cut off the excess I also wedged a roll of tape in the bottom to help keep that round. The cone at the bottom is longer than needed at...

Chems You are quite right, the card board is just to get the shape, it will be strengthened and made air tight later. I would have loved to make it from metal but do not have the skills, so have come up with my own way. By the time I've finished uploading photos today you will see where this...

Onto the cone. This was quite tricky and required a bit of trial and error to get the right length and diameter at the top and bottom. Oh and a lot of masking tape to hold it inside and out. In can't support its own weight so just flops while laying on its side However once sat in the...

Mark

You can see from this photo the card sits tight against the former and follows it perfectly for a perfect circle Mark

Right, I've now made the cylinder and cone and this is how. Starting with the cylinder. It is made from 300g cardboard and needed 2 A1 sheets to get all the way round the formers. I had to buy these but are only £1 per sheet. The seems are joined with masking tape. I initially tried glue...

The supports were paired up and holes drilled for later. The 2 supports for the upper cylinder were then temporarily joined with a couple of supports ready for me to form the drum. Will post some more in a few days Mark

Which left me with 3 pieces cut to the right diameter and a fourth that will become the top and need a smaller hole at a later date I them cut the last mill with the jigsaw and then used a flush trimmer in the router to give the full depth cut out Next was knocking the corners off. In...