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Kupe's Zodiac 650B
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Date:  7-16-2015
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Final Install Baffles

Since I was planning on finishing the spark plug leads anyway, I decided to rivet the baffles into position on the cylinders. Until I rivet in the nylon loom that separates the spark plug leads at the back of each baffle, I can still remove everything fairly easily.

Permanent installation of the baffles included one last session of filing and sanding the baffles to get rid of all the sharp edges and marking rivet holes through the existing pilot holes on the baffles into the attachment flanges already installed on the cooling fins of the engine cylinders. Once marked, I removed the baffles to gain access to the rivet hole marks, then drilled them out to final rivet size (A5). After deburring the new holes, I reinstalled the baffles one last time and riveted them to the mounting flanges.
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From the front: Left side baffle riveted to the cylinder head mounting flange.

From the front: Left side baffle riveted to the cylinder head mounting flange.

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Right side baffle in place.  Remaining cleco holes will support cowling air block attachments.

Right side baffle in place. Remaining cleco holes will support cowling air block attachments.

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