I started working on the baffle seal backup angles. This idea was suggested to me by Rick who was working on an RV10 project with his friend Tom. Tom decided to make these backup angles rather than use the infividual rivets and backup washers. These will make the clamping force on the baffle seal more uniform rather than having numerous stress points on the seal using the typical riveting technique.
I wanted to test the process. I don't have a shear and don't really want to invest in one so I marked a piece of .032 aluminum sheet and cut two lengths of aluminum 3/4 inch wide. I cut them carefully and then filed them straight. I decided to bend the small side of the angle at 1/4 inch leaving the other side 1/2 inch to install the rivets. I was able to fashion tho prototype lengths. A shop at the airport has a shear that I will seek to borrow to cut more pieces as it takes too long to make them good by hand.
The next issue is a matter of conforming the backup angle to the baffle edges. The edges are not straight so they need to be curved a little. Enter Rob and his nice metal shrinker/stretcher. Our EAA chapter has one but so does Rob and he said I was more than welcome to use his. So I got it and set it up and made one piece for a test. Well the piece works well so I decided I will just use it for the #1 baffle backup angle. I was undecided as whether to paint or powder coat them with the baffling.....after texting with Rick I deceded to powder coat them.
I also decided to buy silicone baffle seal instead of using the fiberglass reinforced silicone seal that Vans gives with the kit. There is an endless debate on which one is better on forums but I decided to go with the silicone.
