After considering that I will have this CNC by a shop, why not just make a 1 piece design? It quick evolved to something like this...
Initial test fitting. The o-ring looks nice and snug. And it fits the TB like a GLOVE. This is not very good since I have to consider tolerances of the OEM TBs. They are mostly casted aluminum. Judging by their OEM plastic airbox, I will need to provide more tolerance.