Mesh Installation for High Density Mesh between intake and battery box:

The mesh is going onto an adapter that is circular and 4 inches in diameter. By placing the mesh onto the exterior of the circular ring and making it flush (by bending parts of the wire mesh) and keeping them in place with materials like zip ties, the mesh will be in correct position. Once in correct position, remove zip ties and place 4 inch duct over circular part of the adapter. Use the stainless steel duct clamps that comes with the duct and secure both the duct and the flushed out mesh by tightening the clamp screw. If the clamp is not strong enough to make sure the mesh is secure 100%, either use automotive goop or double sided foam tape to secure the mesh onto the circular ring of the adapter before placing the duct over it.

Mesh Installation for Low Density Mesh at the front of the Car

The mesh installation process for the lower density mesh will probably follow the same process as the high density one. However, if the mesh is attached onto the other side (not the circular portion), the attachment process will most likely differ. The same process of using something like zip ties to keep the mesh flush onto the adapter will happen, but whether being done on the interior or exterior of the adapter is to be decided. If done on the interior, the airflow may be negatively affected. If done on exterior, the mesh may be exposed to natural conditions and might affect the durability of the mesh. As things stand currently, adding the mesh flush on the exterior of the adapter seems like the best decision. If done like this, automotive goop adhesive to keep the mesh in place will work effectively (main concern is to make sure adhesive cures fully so that it cannot break apart due to wind/other conditions).

Moisture Control:

1. Waterproof duct design: Design the duct system with waterproof materials such as PVC or stainless steel. Ensure that all joints and connections are securely welded or sealed with waterproof adhesives to prevent water infiltration.
2. Integrated water repellent filters: Install water repellent filters at the inlet of the duct system. These filters allow air to pass through while repelling water, ensuring that only dry air enters the system.
3. Gravity traps or drains: Incorporate gravity traps or drainage systems at low points in the ductwork to collect any water that may enter and divert it away from the system. Ensure that these traps are regularly inspected and cleaned to prevent blockages.
4. Positive pressure ventilation: Implement a positive pressure ventilation system within the ductwork. By maintaining a higher air pressure inside the ducts compared to the outside environment, water ingress can be minimized as air will tend to flow outwards rather than allowing water to enter.
5. Hydrophobic coatings: Apply hydrophobic coatings to the exterior surfaces of the ductwork. These coatings repel water, preventing it from adhering to the duct surfaces and reducing the likelihood of water entering the system.
6. Baffle design: Incorporate baffles or directional fins within the duct system to deflect water away from the openings and into designated drainage channels.
7. Splash guards: Install splash guards or deflectors around the duct openings to shield them from direct exposure to rain or splashing water, especially in areas prone to heavy rainfall or water spray.
8. Remote location: If feasible, locate the duct openings in areas less susceptible to water exposure, such as higher on the vehicle chassis or within enclosed compartments.

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