The Baffle plans have you rivet the baffles then fit the rubber seals. I decided to fit the seals before riveting as I want to be able to remove/replace each baffle section independently.
Once I worked out the length ( straight run plus 1" overlap) I cut a strip 3" wide and applied masking tape to one edge. I marked a line 3/8" form : * the edge of the baffle and drilled #30 holes * the edge of the seal on the masking tape.
I clamped the seal so that the marked line was in the middle of the two outer holes of the section I was working on and then made a mark with a pen in each hole.
I then used a belt hole punch to make a 1/8" hole at the previously maked positions and then clecod.
Cowl on check - I had to scrap a couple of sections when I saw that the curvature was too much and the seal buckled against the cowl. When you do this yourself you'll understand what I mean.
