I've started drawing out designs on the foam board and begun cutting some of the panels. The construction is slower than expected; cutting foam is not a fast process. So far, I've completed the intake and the most of the test section.
The foam sheets are 20" x 30", so the shapes of the tunnel fit comfortably inside the sheet. The trapezoidal shapes will form the panels of the intake.
I glued the foam panels together with hot glue. I first tried to use epoxy, but I found it soaked into the foam and could not hold pieces together.
I have also laser cut the acrylic sheet with teeth to help joining the two sections.