Thanks George,
The funny bit with the airboxes is that I had to install the lower half "upside down". The PCV connector was located on the bottom, down by the main hetshield and I didn't want to run my top pcv hose down there. It also put the box parallel to the axis of the engine and made it almost impossible to open the cover (problem was fender clearance and voltage regulator locations).

Anyway, I flipped the box upside down. This made the bolt holes mis-align, with only two of each three (the side holes) still lining up. What it did do, was put the PCV nipple up next to the carbs, so I could attach the hose w/o fear that it would melt. I checked carefully and it does not interfer with the throttle linkage or the choke cable. It also puts the box at ~45 degrees relative to the engine's axis, allowing easy acess to the filter.

So... I ask about using a rubber gasket at the carb-to-filter box as I want to "seal" the extra holes and put in some new ones to acomodate the modified setup. I also have some locking washers on the filter bolts. They have little teeth that bite. I'm also going to use some thread locker to keep them in place.

Also that secondary heatshield I mentioned is not part of the PCV system. I know what you're decribing and it not that. This is a formed piece of steel - kinda like a cupped hand. It sits between the filter and carb intake on the front carb, and it cups around the front of Carb#1, "protecting" the cams and adjustment screws on the radiator side of carb#1. Mine's cracked a bit, and the extra thickness keeps the air box from sitting flat across both cabs. It also requires two gaskets.

Finally, The HS6 has five smaller holes around it's intake. three are bolt holes, and the manual calls the other two "Fresh Air Intake" holes. These are blocked by my current air filter (and the old ones too). Should those two holes be open to the inside of the filter??

Thanks!
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1967 P220 Amazon, 1972 145S, 1976 245 DL, 1983 245 DL, 1986 745 GLE, 1990 745 GL, 1995 945....
You mean to tell me that Volvo makes cars that are *NOT* Wagons?!?