Ok, this is a fun project. It’s very time consuming, but turned out very well.
First you have to make a foam plug to get your shape. I chose to use insulation sheets from Sutherlands.
Cut about 4 or 5, 5" inch strips and glue them together with a hot glue gun:
Then you just begin to shape your block using a rasp to the shape you want your snorkel to look like in the end. I recommend that you go about .75 of an inch smaller in diameter than you want because you are going to be adding fiberglass and Bondo later in the process:
Keep shaping until you get the right look, then make your upper piece.
Now go tape off the section around your air box in preparation for a fiberglass mold:
Wrap your plug with fiberglass chop mat. I used small staples to hold the chop mat in place. I would NOT recommend that as they did not come apart like I planned later in the process...grrr.
Lay mat around your air box. Oh...I forgot to mention before you lay any mat give your tape a good once over with Johnsons floor paste wax. This will allow the setup fiberglass to release easily:
Lay your fiberglass resin on your air box and your plug:
Once the fiberglass on the intake box has setup; remove and trim to a neat shape:
Join the plug and the platform you just made together. I used small wire across the top to give the fiberglass something to sit on while it dried and place a heavy object on the snorkel body:
Ok, now that your plug has dried you will need to find the center line and cut it down its center to be able to pull the two half’s apart. This is where those stupid little staples were a VERY bad idea. Anyway, long story short I could not just simply pull the fiberglass off the plug because of those staples, so I ended up destroying my plug to get the half’s apart:
Profile of the JK fender area:
The two halves apart and cleaned out:
While you have them apart, insert and fiberglass in place metal strips, this will be where you will mount the brackets to mount on the jeep to later on:
Taped together to fiberglass together again:
Begin laying your fiberglass over one section of thin chop mat. You won't need much because later on you will be using bondo to smooth everything over:
First of many layers of bondo: