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Bill & Brendas RV-8 QB
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Date:  3-9-2014
Number of Hours:  3.50
Manual Reference:  
Brief Description:  Upper cowl inlet ducts-1

The upper cowl inlet ducts are made of fiberglass and have some contour to them to match the cowl surface. There is a left and a rigt. Instructions say to position for best fit, drill temp holes to secure with clecos. Eventually they get glassed in. Thats it for instruction. No mention of how the transition to the frwd metal baffles are to be done. Very frustrating and confusing. Almost threw in the towl over this today!
Once I had them clecoed in, I started the tiedios process of carving a "swoop in the fwd obd baffles to fit the contour of the duct. Once I could get the cowl on, I moved to the paperclip method for 3/8 incch gap. Eventually got both sides done

Now for the confusing part,,the front baffle! This baffle seals against the cowl surface but somewhere along the line it has to transfer seal to the inlet duct. Thats the issue!! Do we cut the duct so the metal baffle seals as far as possible against the cowl? Or do we cut the metal baffle to match the contour of the duct until that portion of baffle turns away from the duct? Both pose problems for attaching baffle material to seal which I dont think I can describe. I will say that I elected to cut just a little of the duct and a bunch of the metal baffle. I will probably glass in the inbd sides of the duct and hope for the best. I will need to let photos tell the story better if possible. Problem is that I cant get a camera into position for a shot of the problem area at the moment.

I didnt provide photos of the cuts made to the front baffle today but will include them tomorrow....If I dont throw in the towel!!
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L and R upper air inlet ducts clecoed on

L and R upper air inlet ducts clecoed on

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rt side obd fwd baffle cut to 3/8 gap with duct

rt side obd fwd baffle cut to 3/8 gap with duct

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Rt side finished

Rt side finished "swoop" ready for baffle seal

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