Baffles require a lot of attention to detail. The # 4 cylinder baffle also houses the oil cooler on the rear side, so there is considerable fitting required to make it all fit properly. In order to get the top edge the proper distance from the inside of the cowl, I used a small aluminum disc with a hole in the middle for a marker. I then can reach inside and trace on the baffle while rolling it against the cowl to get the proper cut line ½” from the cowl. This requires trimming enough of the baffle to get the cowl in the proper place and then doing the tracing to get it spot on. Because of the iterative process, I can see spending at least a few weeks on getting the baffles in place and fitting properly. Since the engine and proper cooling is the heart of my airplane, I’m planning on taking as much time as necessary to get it perfect. Next time in the shop I plan to mount the oil cooler and start the baffle for cylinder #3. The drawing for the oil cooler installation is OP 27A and is added to the Baffle drawings OP 40-1 thru 14. Construction is straight forward, measure, match drill, cut, file and rivet. So far the pieces are fitting with minimal modifications except for the trimming of the top which is cut to parallel the cowl. The drawings are really very detailed and I and impressed so far with the baffle kit.
