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Kupe's Zodiac 650B
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Date:  8-22-2015
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Baffle Seals Complete

Finished up the baffle seals to the 95th perctile or so - still need some final adjustment trimming. Today I finished updrilling all the attachment holes and deburred them. Then I attached the baffles using baffle fasteners with threadlock on the male ends of the fasteners to keep them together.

With just a single layer of baffle material, the baffle fasteners were too long to hold the baffle seal firmly against the baffles, so I fabricated small "washers" from the baffle material. The washers fit over the male sides of the fasteners and now help hold the baffle seals snugly in place.

I also had a bit of a challenge manipulating the small fasteners with my big hands especially in tight places and as fate would have it, I dropped one of the male sides of a baffle fastener so that it dropped way down in between the #1 and #3 cylinders. The fasteners are aluminum, so my magnetic probe wasn't going to work. Then it finally hit me - Gorilla tape! I attached a thin strip of that stickiest-of-all-tapes over the end of a long, thin screwdriver with the sticky side out. Then I blindly poked it down between the cylinders (where I couldn't even see the fastener!) and it came right out on the first try. It also worked on the first try the other 3 times I dropped a fastener into my cylinders!
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Lef side baffles with seal attached by baffle fasteners.

Lef side baffles with seal attached by baffle fasteners.

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Both baffles with seals installed and trimmed for fit.

Both baffles with seals installed and trimmed for fit.

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my screwdriver with the Gorilla tape sticky end - perfect for retrieving fasteners!

my screwdriver with the Gorilla tape sticky end - perfect for retrieving fasteners!

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