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Matt Dralle
Site Admin
Joined: 08 Nov 2005
Posts: 25858
Location: Livermore CA USA
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 Posted: Mon Sep 14, 2009 6:01 pm Post subject: Initial Baffle-To-Top-Cowling Fit... |
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Dear Listers,
The RV-8's cowling done and fits like a glove. I started the baffling last night and its coming along nicely. The fit on the sides and back are very good considering the IO-390 installation (and the use of the IO-360 baffle kit). The front baffling is completely different, however, and I'm slogging through the custom fitting.
But here's my question. I decided to put the top cowling on top of the baffling that I've got installed so far and I was shocked that the baffling appears to be a good 1 to 1.5" too tall!! Is this because of the IO-390 or is that just where Van's expects you to start in your "cutting-it-down-to-size" phase? That's a lot of snipping and fitting and snipping and fitting. I was expecting to have to trim some, but not over a inch...
Also, it looks like the over-sized oil cooler is going to fit nicely on the rear baffle with only a little "modification". But I'm not sure if the back, upper corner is going to clear the cowling. Since the cowling is sitting over a inch high right now, I've got no way to really trial fit the oil cooler and check for cowling clearance until I trim the baffling down. Worst-case I could put a blister on the cowling for the rear, upper flange of the oil cooler, I suppose, but that's kind of hokey. There is room to move the oil cooler in towards the centerline about 1", but then the mount will no longer line up with the flange on the outboard edge and will require more modifications.
Thoughts...?
Attached are some pics. ( Digest viewers check http://forums.matronics.com ).
Matt Dralle
RV-8 #82880 N998RV
http://www.mykitlog.com/dralle
Baffling and Oil Cooler...
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rv6n(at)optonline.net
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| Posted: Tue Sep 15, 2009 5:22 am Post subject: Initial Baffle-To-Top-Cowling Fit... |
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Matt C
6nbsp;
It has been about six years since I made my baffles on my RV6 with an 0-360 but I remember having to trim quite a bit E 6nbsp; I must have had it on and off a few dozen times to get it to fit perfectly E 6nbsp; Having seen your progress from your postings I am certain you will get it right C just trim a little at a time C check and repeat E
6nbsp;
Forget about having a blister on the cowl for the oil cooler C you will have to address the mount after the cowl fits E
6nbsp;
Good luck C
6nbsp;
Bob Bales
do not archive
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Paul Valovich
Joined: 11 Jan 2006
Posts: 75
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| Posted: Tue Sep 15, 2009 7:06 am Post subject: Initial Baffle-To-Top-Cowling Fit... |
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Matt,
Seems like I’ve been working on the baffles for years – but its been several months! It’s a slow tedious process. – Tonight I’m going to rivet the airseal fabric and declare victory.
I’m building an RV-8A with a new Aerosport IO-360. The thing that bothered me most during the baffle saga was the amount of metal material I had to remove in order to get the 3/8-1/2 inch baffle to cowl clnc. And the difficulty I had getting the cowl to fit over the oil cooler (standard Vans) corner. I’d estimate I removed a third of the metal is some areas.
As I got closer I used a zillion large paper clips set next to each other all around the baffles to get final shape / clnc. Basically, set a zillion paper clips, attach – or place the cowl where baffle interference prevents attachment - cowl, mark 3/8-1/2 inch from top of paper clips on baffles, remove baffles, trim baffles – usually in 1/8 inch increments, reattach baffles – and repeat ad infinitum.
After getting the final shape, I worked with the airseal fabric – 1 inch below and 1 ½ inches above baffle contour. Drilled and clecoed airseal fabric to baffle – then fiddled with corners – including lacing – to get the best seal possible.
I went through my adjective vocabulary many, many times.
A related question for the assembled expertise: I have one Lightspeed and one mag. Are blast tubes needed – or can I leave a small gap along the bottom of the rear baffles to provide some airflow aft of the baffles?
Paul Valovich
N192NM Reserved – again
Ridgecrest, CA
[quote][b]
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halbenjamin(at)optonline.
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| Posted: Tue Sep 15, 2009 6:22 pm Post subject: Initial Baffle-To-Top-Cowling Fit... |
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Hi Matt C
6nbsp;
Keep trimming little bits at a time C you 7ll get there E The oil cooler on my didn 7t fit well at all C so I tipped it back at an angle E It wasn 7t hard to do E E EJust another thang E Attached is a picture E 6nbsp;Good luck!
6nbsp;
Hal Benjamin RV4
Long Island C NY
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Matt Dralle
Site Admin
Joined: 08 Nov 2005
Posts: 25858
Location: Livermore CA USA
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| Posted: Tue Sep 15, 2009 9:23 pm Post subject: Initial Baffle-To-Top-Cowling Fit... |
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I just wanted to thank everyone for the great feedback on this baffling cut-down procedure. I'm glad to hear that it wasn't just my installation!! 
I'll post some more pictures when I get things hacked down to size and that oil cooler mounted.
Hey, check out my newly registered URL for my RV-8 Building site:
http://www.mattsrv8.com
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com
Baffling and Oil Cooler...
At 07:00 PM 9/14/2009 Monday, you wrote:
| Quote: | Dear Listers,
The RV-8's cowling done and fits like a glove. I started the baffling last night and its coming along nicely. The fit on the sides and back are very good considering the IO-390 installation (and the use of the IO-360 baffle kit). The front baffling is completely different, however, and I'm slogging through the custom fitting.
But here's my question. I decided to put the top cowling on top of the baffling that I've got installed so far and I was shocked that the baffling appears to be a good 1 to 1.5" too tall!! Is this because of the IO-390 or is that just where Van's expects you to start in your "cutting-it-down-to-size" phase? That's a lot of snipping and fitting and snipping and fitting. I was expecting to have to trim some, but not over a inch...
Also, it looks like the over-sized oil cooler is going to fit nicely on the rear baffle with only a little "modification". But I'm not sure if the back, upper corner is going to clear the cowling. Since the cowling is sitting over a inch high right now, I've got no way to really trial fit the oil cooler and check for cowling clearance until I trim the baffling down. Worst-case I could put a blister on the cowling for the rear, upper flange of the oil cooler, I suppose, but that's kind of hokey. There is room to move the oil cooler in towards the centerline about 1", but then the mount will no longer line up with the flange on the outboard edge and will require more modifications.
Thoughts...?
Attached are some pics. ( Digest viewers check http://forums.matronics.com ).
Matt Dralle
RV-8 #82880 N998RV
http://www.mattsrv8.com
Baffling and Oil Cooler...
|
| | - The Matronics RV-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV-List |
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Matt Dralle
Matronics Email List Administrator |
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