As the ZX12R engine runs unusually hot, we found need to direct the air-flow straight into the radiator. We used expanding foam to block up the space between the radiator and the nose-cone. Following covering the radiator, horns and other objects around the radiator, we squirted in the foam. This was left for 24 hours until cured. The nose-cone was then pulled away, leaving the formed shape behind. The cured foam was then trimmed up carefully and painted in black weathershield paint.

So, once we got the air into the radiator, we then had to decide how to get the hot air out of the engine bay. We knew we would have to cut into the bonnet behind the power-bulge to let the heated air escape. The following pictures and descriptions tell you how we did it.

Firstly we used a fixed point in front of the nose-cone for us to allow string to be pulled tightly down the sides on the power-bulge to the rear of the bonnet. This position was marked. We then moved the string in at the rear of the bonnet to give us a new projection to the centre of the fixed point, we marked this point. Joining up the points we arrived at a suitable size for the holes we needed to cut into the bonnet. After agreeing amongst us the radii we needed to use, we began to cut.

Following rough cutting of the holes we could then begin to form the final shape. The cutting out was extremely carefully done for obvious reasons.

Just finalising to do, then we could prepare the backside using rough glasspaper to provide a key with which to hold the black painted mesh with P.U. adhesive. We painted the B&Q steel mesh with gloss black paint for protection.

One of the bonnet cut-out's complete ready to be fitted up with the mesh.

Once the rear of the holes had been keyed we then placed the mesh into the pre-placed P.U. Adhesive and rubbed it into the grid's providing a good hold. The mesh was pulled into place using wooden blocks on top of the bonnet and string used to pull-up the mesh to take the shape of the curved bonnet. This was then allowed to cure overnight.

Whilst this was curing we began to manufacture aluminium darts to be placed on top of the mesh. This will help to reinforce the mesh and to also help it look a little classy

These were manufactured for some leftover bits of aluminium we have laying around the garage. The inspiration came from the Mercedes SLK 500 AMG/McLaren.

The rear parcel shelf has already been replaced with a lifting version using black vinyl instead of the grey. This allows us to make use of the space behind the rear bulkhead as bootspace.

More pictures to be posted later but these two are indications as to what is going on.

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