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Jims Web Site
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Date: 11-5-2011
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Number of Hours: 48.00
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Manual Reference: (none)
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Brief Description: Started engine baffles
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I found an engine baffle pattern for an O-200 in Tony Bingelis' book, "Firewall Forward." While the exact height of the parts was uncertain, the pattern around the engine itself appeared usable.
1. Traced grid onto 2024T3 .032.
2. Cut out part.
3. Deburred, etc.
Part was a poor fit.
ITried using a paper grid for aft and side baffles:
4. Traced patterns onto stiff paper,
5. For each baffle:
A. Positioned on engine, and removed any excess paper.
B. If the pattern was not big enough, added snippets of masking tape as required.
C. Taped pattrern onto 2024T3 .032.
D. Using pattern as a mask, sprayed with red paint.
E. Cut out metal, and deburred as required.
F. Made suitable bends on brake.
G. Fit check.
Note: High rate of scrappage, but I ended with the necessary side and back baffles.
5. Using the top and bottom cowls as reference, developed a paper template to cut the top of the side baffles.
6. Cut away excess material with tin snips.
7. Using the top cowl, developed lofting lines from left to right at the rear baffles' station.
8. Made paper templates from lofting lines.
9. Markled and cut rear baffles.
10. Fit check with cowling, and belt sanded until a fit was obtained.
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Laying out grid on metal
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Cut out part
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Making side paper template
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