Baffles Assembly

September 27, 2019 – I am continuing to assemble the baffles.

The pictures I seem to have right now are for the left rear baffle, including the provision for the oil cooler.

Back when I started the baffles, the instructions have you go ahead and cut out the hole for the oil cooler. That’s misleading; you really can’t / shouldn’t do that until everything is fitted with the cowling.

The oil cooler support brace is pre-drilled, and the holes need to line up with the doubler for the cooler. The trick is locating these two pieces together, since they are on opposite sides of the baffle. There are also flanges on the sides of this brace, that are pre-drilled, but shouldn’t be. These holes are useless, since the brace needs to be located up or down depending on where you can fit the cooler, and the top of this brace gets a pretty radical trim to fit the upper cowl. So I ignored those holes and drilled my own where it made sense.

You can see in a couple of these how high this brace is in relation to the top of the trimmed baffle. I based the location of the cooler on the ability to use some of the side flanges in the brace for some support. I wanted the cooler as high as possible. There is no interference here, and I don’t even have to trim the flange of the cooler to clear the engine mount, like some people have had to.

I needed to make sure the rivets and fasteners in this area cleared the cylinder. One place I thought was interesting was the inboard vertical line of fasteners for the doubler. The flush heads of the rivets need to face the cooler, which puts the rivet shop heads against the cylinder. The holes line up perfectly between cooling fins on the cylinder.

I assembled this baffle as needed. I didn’t install any fasteners on the outboard vertical flange, since this may get an additional support angle to help prevent cracking later on.

Here’s the baffle in place.

I also made the cutout for the ignition lead seal, and I drilled a hole for the cooling blast tube for the mag.

I’m just working my way around the engine, polishing cut edges and assembling the baffles as needed. I’m also drilling holes for other items, like the fuel line which comes from the Red Cube up to the flow divider. This fuel line will pass through the right rear baffle. I think I’m going to “permanently” install the baffles before I do the seals.

Time: 8:00

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