Having already dimpled and deburred all the holes, I decided to rivet the oil cooler baffle/doubler. I had previously made the air deflectors that are at the top and bottom of the cooler that don't show up in the pictures because they are under the cooler. I used the pneumatic or hand squeezer on all the rivets. I then installed the oil cooler to check for the final clearance from the engine mount tube.
I hope the final clearance of 1/4" is enough during the engine start/stop shaking. If not then I'll have to redo the setup somehow. Van's recommends approximately 1/2" clearance. I'm hoping the beefed up baffle/doubler is rigid enough to allow the cooler to keep its clearance from the mount. All part of the risk involved when deviating from the normal plans while putting the "experimental" into the word experimental. Also possibly putting the word "costly" into the word experimental.
The bolts go through 6 layers of metal at the baffle/doubler interface.
