I just couldn't fathom making cuts and mistakes on the actual baffle material, so I traced it onto a piece of posterboard and did 90% of my fitting and trimming with that pattern.
Then I transferred the results to the actual baffle, where I spent much less time tweaking it to fit.
The 3 pictures below are of the posterboard pattern.
The photos on the 2 log pages with the same date, are photos of the rest of the work with the actual aluminum baffle.
