Quick one month functionality update on the cabin air intake duct/filter design. At least 500 miles logged since installation, and while I haven't run the AC for all of those miles, a number of 1-2 hour trips with the AC running at all fan settings. Temps ranging from 90+ to high 40's/low 50's. Mix of dry and wet weather over the month. Mostly road use but some dirt and gravel use as well.
Observations when opening the cowl this morning for a look-see:
Slight musty smell detected when running the system from cold, in particular after a stretch of wet weather. The odor dissipates after a few seconds. I believe this has nothing to do with the duct/filter and everything to do with the sub cowl being a bit of a breeding ground for funk since it tends to stay wet/damp long after the weather passes. For reference, I had an '07 BMW E90 and that thing smelled like a farm yard every time I used the system, even with a fresh filter and Lysol-disinfected ducting. Not too worried about the Jeep.
- ABS plastic prototype assembly shows no signs of damage due to exposure to temperatures and vibrations - appears "as installed"
- All subcomponents appear to be functioning as intended, no cracking or splitting at joints or anywhere else
- K&N VF1010 filter appears to be relatively clean and free of debris
- Hint of rust on cartridge housing speed nut, no surprise and nothing I'm worried about. Factory speed nuts for the cowl panel look far worse.
- Filter housing and duct beyond filter show no signs of air leakage inside (no trace dirt)
- Foam seal seems to be doing it's job, no evidence of water infiltration between duct and sub cowl, no water in footwell from the cowl
- No evidence of contact with underside of cowl panel, the design seems to give sufficient clearance to any existing physical features
I realize this isn't a long term test, but I think I'll leave that up to whoever might be interested in trying out the design for themselves. I've got a few minor modifications I'm making to some of the parts to improve the overall design. I may create a cartridge box that will accept standard filters as this one is specific to the VF1010 and I realize some might not want to spend the loot for the K&N. I'm also considering an optional cartridge box door/air horn design that may improve weather proofing even more (though this has not been an issue for me personally).
Beyond that, I'll likely upload all of the files here for anyone with a 3D printer to download and try out, along with some caveats and tips for printing, assembly and installation.
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Man i gotta say that is a pretty clever design my man good work!
Every time i see something like this just gives me another reason to get a 3d printer, im not too handy in CAD or sketchup but i can make some stuff...kinda
Was nice to drive it again after about a month hiatus, LOL. I also finally put my hook on that I got for 
