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Bill & Brendas RV-8 QB
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Date:  3-1-2014
Number of Hours:  4.50
Manual Reference:  
Brief Description:  Cut in ignition wire holes to rear baffles. More r

The plan to have baffles fitted by end of Feb didnt happen. Now Im hoping for mid March.
Started by making a new angle for the left ramp to #2 cylinder baffle to increase clearence for the conical gusset and baffle seal. After about half hour, I scrubbed the attempt and tried just taking some angle out of the bend in the ones I already fitted. That did more than I thought it would! So I moved on

Rivited the angles to the ramps and the fwd cylinder baffles left and right. This required a combination of tool and methods to get done though it looks to be easy.

Rivited on the stiffners to the rear cylinder baffles

Applied fire barrier 2000 around the air intake hole in aft case baffle, cut and attached the screen and scat tube flange to the baffle with clecos. Applied a bead of the silicone around the flange edge as well. After its cured, I will rivit in place.

Drilled mounting holes for the ignition wire pass thru protection pieces and then cut in the oval holes that will allow the nylon seals to sit flush. I used a combo of drill bits and dremel to get a rough opening and then finished pout with rotary file and hand sanding.

Drilled in two holes for blast tubes to cool magnitos. Drilled to plans with step drill. I made sure to put level with or lower than top mount hole in rear center bracket so that id be of no issues after trimming baffles to fit with top cowl.

Trimed and sanded and polished the radius relief on rear case baffles that meet up with engine case to take some pressure off the fit.

Need to remove scratches from fwd ramps with wet dry 600-12oo grit paper and then use some Purple polish to buff out some shine later. This stuff supplied by a fellow builder who had good results. Thanks Mike!

I also need to make two conical gussets and then rivit on. Then I should be ready to start cutting top baffles edges to fit cowling next. Lots to do yet!
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Rt side ignition harness seal hole ruff in

Rt side ignition harness seal hole ruff in

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Rear case baffles ignition harness pass thrus seals loose install

Rear case baffles ignition harness pass thrus seals loose install

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Front ramps rivited to obd angle and cylinder baffles

Front ramps rivited to obd angle and cylinder baffles

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