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Rob's REBVAIR Project
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Date: 11-13-2014
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Baffling part 8
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While waiting for parts, I decided to just tackle the baffling. The 9 ft. roll of silicone baffling material is the more expensive stuff with the fiberglass sandwiched in between ($70), since previous experience with the plain pure-silicone material showed that a clamping force (like a rivet or screw) will 'warp' the material around the hole, thereby compromising the silicone-to-aluminum contact. Didn't matter in that particular application, but lesson learned was that the fiberglass stabilizes the flat shape of the silicone so less air will leak past...the whole purpose of this excercise.
Obviously the most challenging parts were the semicircular areas, and test-fitting/trim iterations, but all in all I think it will work just fine. There are a few pin-point gaps here and there, but by all accounts, the engine is easy to keep cool, so I think my level of diligence is adequate. I can always redo it if I find it isn't cooling well, or plug up the leaks with something.
I made all the rivet 'washers' out of 0.032" stock mostly because I didn't want to pay and wait for an order of aluminum washers to comeback. These prevent the rivets from pulling through the soft silicone material.
Image 2 shows some 0.032" angle stock I made to help all the straight areas sit tight against the aluminum baffling.
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