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Marlins Web Site
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Date: 10-25-2022
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Number of Hours: 6.00
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Manual Reference: OP-40
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Brief Description: Cut Outboard Baffle and Floor-Baffle Flanges
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The first thing I need to do is to figure out how much to trim (cut) the side baffles and the front-floor baffles (CB-710A & CB-1002A) to clear the bottom cowl. Here’s where the OP-40 plan instructions and diagrams, once again, are not good. If they had broken the diagrams into multiple steps, with multiple drawings, it would have been extremely helpful. After attempting to get the bottom cowl aligned, I first started vertically trimming about an inch off the side baffles (CB-1009A & CB-1003A) to clear the front of the bottom cowling. These two baffles will need to be cut lots more but at this point, its not clear how much. After trimming, 1 then 2 inches off the front of the side baffles; the front-floor baffles (CB-710A & CB-1002A) hang over the bottom cowl by at least 3-5 inches. There doesn’t appear to be any way to accurately mark where to make the cuts because the lower cowl can’t be raised anywhere near it’s final position. After about an hour of trying to guess where these cuts needed to be, I finally made paper templates of the floor baffles thinking I should be able to mark the templates and transfer to the actual baffles. In theory, this should work but after some trial and error I realized because the floor baffles are angled downward and I couldn’t be sure I had the bottom cowl in its actual final position, the mark on the template could be as much as ¾” either too short (which would be a very bad thing) or as much as ½” too long. I have to find another solution. Six wasted hours on this. I guess it’s time to go home for the day and see if I can think of better solution.
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OP-40 Front & Side Baffles
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Side Baffles 1st Cut
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Marking Paper Template
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