Nov 24, 2022     Baffle seals - (4.5 hours)       Category: Firewall Forward

1. Began fitting some of the baffle seals -- at least the ones I could fabricate out of the 3" wide seal material I currently have. (The large piece I ordered will be here in three days.) First, I cut out and began fitting the two narrow seal strips that will go under the cowl inlets.

2. I cut and fitted the #3 cylinder piece, drilled five attach holes for the #8 screws, used a leather punch to finish the holes in the seal strip, then attached the piece with some screws and clecoes. I decided the 1/2" washer screws I have are just a little too long, so I ordered some 7/16" length ones, along with some MS21045-08 locknuts.

3. Opened up one of the two cooling air holes in the back of the #4 cylinder baffle to accommodate the 1" flange and hose that will cool the engine-driven fuel pump.

4. Final-shaped several of the side baffle pieces.

5. Measured out, located and marked all of the attach holes for the baffle seals on 9 of the baffle pieces. (I still have to do this for the two front pieces). Removed all the baffles, then drilled and deburred all the #8 screw holes.

6. Re-installed all the baffle pieces.

As soon as the baffle material gets here, I'll be ready to cut out the seal pieces using the templates I made yesterday, then match-drill them to the baffles.