Trimmed the upper baffles to fit the upper cowling. In the first image, there is a lot of interference on the aft baffle. I layed a Sharpie along the inside of the cowling and traced the contour onto the baffle. Initially there were only a few places where the Sharpie touched the baffle. After several passes of whittling the baffle away, I got the cowling to be low enough to insert the retaining screws and have about 1/8" clearance to the baffles. I ended up removing about 1" from the top of the center baffle, P01-45, trimming about 1/8"-1/4" at a time.
The only information about how much gap there should be between the baffles and cowling is "within 1/2" of the cowling". No minimum is specified. The "bulb" on the seal is 9/16" high and rather stiff. Unless the seal is installed to fold over as in image 3, the bulb will need to be compressed along the flat edge. The images in the instructions suggest the bulb is compressed along the straight edge, suggesting a gap closer to 1/2", not the 1/8" I have. I may need to go back and trim more off the top of my baffles.
After trimming my baffles, it's apparent that a number of the strip retainer templates on the plans won't work. I'll need to scratch build those.
Big gaps at aft baffles
Rear baffle after trimming
Baffle seals folded over 90 degrees to fit contours?
