Trimmed baffle tops to fit cowl

September 20, 2019 – I got the tops of the baffles trimmed to where the top cowl can be installed, plus gave room for the seals.

I went to the aircraft section of Kroger and bought paper clips. This is a trick I’ve read about in the RV community. In fact, at lunch today I was talking to a guy who was doing baffles on a different type of airplane, and I mentioned the paper clips. He was amazed…  By the way, for the record I bought 120 clips.

I placed them around the baffles, high enough that I knew they would make contact.

I set the upper cowl in place, and removed it again. This gave me the initial clearance.

The one big conflict I had was at the aft left corner above where the oil cooler will be. I ground a radius there, reset the clips, and verified everything by doing it all again.

The instructions for the baffles call for a 3/8″ – 1/2″ gap to allow for the seals. I measured and marked 1/2″ from the top of each clip.

This gave me my cut line all the way around.

After the cuts, I reset all the clips and verified the cuts.

I removed my FOD protection and looked everything over. I just have to clean up and deburr the cut lines. I’ll do that on each baffle individually.

I made and attached the small clips that secure the forward and aft side baffles to each other.

I also made the cutout for the right side plug wires. This cutout is for the top wires that pass through the rear baffle.

That brought me to a good place to stop for the day.

Time: 6:00

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