Brief Description: Modified Baffle for Oil Cooler-Incorrectly!
I drilled the side of the left center baffle to the left outer baffle in two places and drilled the left outer baffle to the plenum. I determined the edge of the left side of the baffle for positioning the oil cooler. I marked the inside lines of the doubler on the baffle and used the cut-off wheel in the Dremel to cut out the opening for the oil cooler. The doubler had the interior ends curved outboard toward the oil cooler. I will be installing an oil door shutter, with which the curved ends interfere. Before cutting them off, I decided to attempt to hammer them down, which was successful. After drilling holes in the corners and using the Dremel cut-off wheel, I clamped the doubler in place and drilled almost all of the predrilled holes to the baffle. All of the edges were cleaned up and the holes deburred. I then clamped the baffle in place on the engine and discovered that the doubler and the hole in the baffle had been located too low. The bolt hole for the cooler on the right side will have a nutplate riveted to it on the engine side of the baffling. The center screw hole will have the nutplate installed too low. The access hole in the baffle can be raised by at least 1/2," so I will order another baffling piece and recreate another piece.
Placed another order with Van's tonight.
The doubler and the hole cutout marked on the baffle
The doubler and the baffle after trimming
The doubler clamped to the baffle for transferring holes to the baffle
