Here is the status of the baffling. These three entries cover a weeks worth of work. The end goal is to have 3/8 to 1/2 separation between the metal portion of the baffling and the cowling. It is a slow process of determining the current separation and trimming appropriately. Before you can really determine where you are the cowling has to fit down over the baffling material, THEN you can set the separation. But that requires trimming the baffling and you don't want to trim too much material away.
I copied a technique of placing paper clips on the baffline and setting the cowling in place. The paper clips are pushed down by the weight of the cowling and that shows your current separation. It is a very slow process, in part because I did not want to over trim. So I would only take off an 1/8" or so at a time. As the cowling got closer to sitting in place the more difficult it was to determine where to trim.
