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For ducting to fit other geometry inlets on various cars, consider plastic plumbing ducting at Lowes and Home Depot, etc.. Some of this stuff is fairly thin wall, perhaps can be stretched or formed somewhat with a heat gun, and being plumbing ducting already has smooth internal contours and shapes, for better flow.
Another possibility is to make a male mold for the particular duct shape out of polyurethane foam and Gorilla glue, sand to exact shape, wrap with aluminum foil, and then lay up fiberglass over it to make a corresponding female duct shape. Or, use such male mold as a master, and thermoform PETG or acrylic sheet over it to make the duct.
I'm also wondering about use of 2 liter PETG plastifc soda bottles, heated with a heat gun and stretched or reformed to particular shape, for ducts.
Thoughts?
YouTube for "PETG" and see how ductile this stuff is. It's in virtually every clear blister pack or soda bottle around. Tough, clear, cheap.
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