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Rob's REBVAIR Project
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Date:  5-5-2014
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Engine Baffling Part 5

I had been procrastinating on this one for some time, but with the aluminum baffling largely complete, I ran out of excuses. The corvair as installed in the car has some formed steel baffles, and these 4 items are critical to correct airflow around the cylinders in a flight engine as well. The first two are under the cylinders themselves, (hard to show at this point). The second two are at the rear of the engine. In image 1, you can see where I heated, formed, and welded an area of the baffle that was contacting the baffle under the cylinders. It's perplexing to me where this interference comes from, since both are stock items and in their stock locations, but when I asked Roy Szarafinski (5th bearing fabricator), he said he routinely had to heat up this area with a torch and forcibly bend it to eliminate the interference. After studying this for a while, I determined that it would be noticeably easier on the baffle if I cut some relief slots first.

After heating and lightly hammering for about 2 minutes, the rough shape had been acheived, and I then welded the area (poorly) to secure it. It all went fairly smoothly.
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Final product

Final product

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