Using the paper template I made yesterday I began work on the curved gussets. The plans call for bending this over the edge of the table keeping the narrow end on once spot and rotating the part about this point over the edge of the table to get the curve. I thought there must be a better way. I took the rubber drums from the oscillating drum sander; there are about 5 diameters of sanding tubes. I used these hard rubber parts to make the curve!
Now it was time to cut the top of the baffle to match the contour of the cowling. To do this I borrowed an idea from another builder. You clamp the upper cowl above the lower on with popsicle sticks high enough to get your arm inside. Then make a marking device that marks a line the same height. You could add the gap you want between the baffle and cowl. I did not do this because I was not sure how this method would work, I marked for a flush fit between the cowl and baffle.
I started to make the trim of the rear baffle and I have a ¼” gap in places, so even though I marked for a flush fit it was off some.
