Here is a picture after the glue up and a report on the glue. The 3M 4220 plastic mender comes in two large syringes. The 3M tool to squirt these is about $75 and is a good investement for a body shop. I cut two equal length dowels and used a standard caulk gun to push on the syringes. I sealed the two long seams along side the trumpets with one long smooth nice looking bead from the outside of the case using one of the self mixing tips. I smoothed the inside with my finger. This is really about all the time you have with this glue. Less than a minute before it starts to set up.
I used a second self mixing tip for the air inlet. I put a bead of sealer under the 4 inch plastic flange and on top of the plastic flange followed by the aluminum inlet and then four screws. I just barely got them tight before it all turned into a brick.
With the tips used up I then mixed the glue on a piece of heavy polyethylene. It is very liquid when it comes out, mixes and starts to stiffen very quickly. I applied it like putty to the inside of the plastic flange to smooth the air transition into the box. This worked OK but was not very smooth when I finished. I sanded it smooth and rounded off the corners. It sands and feels like a hard rubber when cured. The outside looks very much like the previous photo. Not much mess there.
It may be that Suzuki offers replacement trumpets at a reasonable price. This will allow some length and diameter tuning. Mine are a bit large in diameter, so maybe they are from the 1000 cc bike.
You might think this is a lot of work on an airbox until you price one from an aftermarket supplier.
John
