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Bob's RV-8 Build Site
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Date:  12-31-2022
Number of Hours:  4.80
Manual Reference:  
Brief Description:  Baffle Conical Gusset

I decided to start by working the conical gusset. According to Vans instructions you simply cut a piece of .032 aluminum sheet and then holding the rear of the gusset on the table edge simply roll the large radius on the edge of the work table. Yeah....sounds easier than it is!!!!

As I often do I cut a piece of poster board and played with a couple renditions to make a pattern. It took me a while of trimming and revising but finally I had a good pattern that would work. I cut the pattern out on the sheet metal. As far as getting the gusset to fit......that was a PITN!!! I used Vans method on a limited basis....and I used plastic pipe......aluminum rod stock and my hand to finally finess the conical gusset to its final form to fit as required.....took a lot of time!

I moved to the side baffles and measured, marked, and drilled the baffle clips that hold the number 1 & 3 and the 2 & 4 baffles at the split line and give extra support. Easy peezy....

Finally I was looking at the oil line that feeds the governer for the prop. I began to ponder how I was going to get the hose to fit better as it binds a little bit on the hole....so I am figuring out options for a bigger hole or other fittings.....TBD!

Well.....I built on the project at the speed of snail this year and put in 709.7 hours in 2022.
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Conical Gusset.....PITN

Conical Gusset.....PITN

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L & RSide Baffle Clips

L & RSide Baffle Clips

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Pondering the plumbing......

Pondering the plumbing......

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