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Don,
I don't know if this option is available to you, but I'll throw it out
there anyway. On my ES, I needed both exhaust blisters and an intake scoop
for my Lycoming installation. Fortunately for me, there's a Legacy being
built in the same shop where I built my plane that has a cowling for an
IO-540. I borrowed it and did 3 BID releases of the tunnels and intake and
we used them to form the lower cowl in the attached photo. Once they were
in place, we put some additional BID over them to stiffen them up. The
Legacy tunnels are a bit smaller than the ones on the IV's, but I'm very
pleased with the way they came out.
Another more expensive option would be to just buy a IV cowling to begin
with, but as I found out when I checked, they ain't cheap and it sounds like
you're beyond the point where that's a viable option.
Good luck,
Skip Slater
N540ES
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