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Zenith CruZer & Sonex Logs
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Date:  7-18-2011
Number of Hours:  3.20
Manual Reference:  SNX-P30
Brief Description:  Engine Baffles

Started the installation of the remaining engine baffles.

First up was to position the upper oil cooler baffle to determine cowl interference. Quite a bit. Made multiple trim-then-test attempts before finally resulting in the shape in pic 2 below. This is just a bit more trimmed-off than I would have liked, but still can be handled by the rubber gasket material.

Next, I dug out the remaining baffle parts. Most had to be bent to fit - either to fit the engine or to provide mounting tabs for riveting to each other.

Had previously test-fitted the right side lower and corner baffles when I was installing the exhaust pipes & EGT probes - I was concerned at the time that the baffles would interfere with the probes. Today, I finished bending the remaining parts. Performed significant griniding work getting the left lower piece to fit around the exhaust pipe. Also had to perform some surgery on the right corner piece - as provided, it would sit up about 1/2" too high on the head, so I cut it into two parts; will bend and rivet-together to obtain the correct height.

Cut, marked, and piloted the 4 angle pieces that hold the side baffles in place. After bending the tabs for the sides, I marked the positions of the sparkplug leads on the rear baffle. Since the side baffles attach to the rear baffle, I had to cut relief holes in the side pieces to accomodate the plug wires.
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Upper oil cooler baffle - pre-trimming

Upper oil cooler baffle - pre-trimming

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Upper oil cooler baffle - post-trimming

Upper oil cooler baffle - post-trimming

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Front baffles bent and just set in place

Front baffles bent and just set in place

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