Almost per plans...
I started making baffles using the plans but with tapered fins on the cylinder barrels, will have to modify the cylinder fin baffles.
Here's a template for ECI tapered cylinder baffles if using the Vans baffle kit:
http://www.prettybits.com/files/Tapered_Cylinder_Baffle_Extensions_Continental-ECi.pdf
https://images.app.goo.gl/SgHcrgonccf1auMb6
The first parts were fairly easy to make.
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| The top cowl makes contact. It's easy to see in the rear of the cowl. |
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| I used a sharpie on a stick to mark cut lines. Initially I trimmed for 1/4" clearance but later, the plans specify 3/4 to 1.5" clearance over the heads to allow for engine movement. |
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| A typical problem I have is getting tired and making mistakes. I was using the small M drawing and didn't realize that this template and was split onto another page. |
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| The plans template was close but I changed the cut/bend lines a little to match these heads better. I'll round the corners, debur and sand the edges. |
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| Nutplates were installed on the #3 cylinder head baffles to help hold the forward sections in place. |
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| Nutplates installed on #4 cylinder head baffle. |
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| Another area the plans templates don't match due to a different starter and alternator. |
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| The plans template didn't quite match the #4 exhaust pipe so I used some scissors and tape to adjust the template. The SDS fuel injector protrudes. |
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| The band saw has size/width limits of a little over 13". |
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| The aft baffle at the #1 cylinder. |
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| A bottom baffle support bracket that bolts to the starter. (Not in the plans) |
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The top left brace was added to stabilize the top of the aft right baffle. The per plans baffles would be attached in this area. |
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| Tapered baffles with the hanger reinforcement wire and small beads of silicone adhesive to reduce abrasion. |
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| Safety wire routed through some Nylaflow. |
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| Modified M34 #6 template. |
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| This one is per plans. It wasn't clear to me what/how to use two double loop safety wires so I twisted to .041 wires together as one and threaded it through the 1/8" holes. |
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A template posted on the RV forum was used for the barrel fin baffles.
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