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Zenith CruZer & Sonex Logs
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Date: 8-4-2011
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Number of Hours: 2.30
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Manual Reference: SNX-P30
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Brief Description: Baffling Drill / Cleco
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Wow.14 days without working on the plane. Well, AirVenture Oshkosh was there for 9 days, and of course there was pre-departure work and some catch-up upon our return. Then there's the bloody heat. It's been 110 every day this week since our return, and it's horrible out there. Finally was going to start up again today in the AM - and our power went out. 5 times all told; longest was 2.5 hrs, least was 15 minutes. Still, you think all is well and you start to work, and ....
Tonight started cleco'ing together the baffle parts. Up until now, all work was just trimming and fitting without drilling any holes to hold it all together. Tonight continued the trimming where required, but also cleco'd just about everything together.
The front pieces (6) can be riveted together. The can be removed from the engine as one assy. They are then held to the side pieces, which are held to the back piece, by self-tapping screws to allow removal of the side pieces for maintenance work (like retorquing the head bolts).
The left front (right side in the pics) piece created some problems. As per the plans, there was no way it would fit, so I cut it into two pieces. This allowed a good fit, but created a gap as shown in pic one below. I created a filler piece shown in pic 2 to solve that issue. Also spent quite a bit of time creating a tie-strap for the front lower side in this same area; the pieces were close, but no overlap for riveting, so I custom-fit a strap to hold them together.
Next worked on the side pieces. Used an angled rivet step (rough tip) bent and held by vise grips to mark the holes from the angle pieces screwed to the head onto the side baffles. Drilled and cleco'd.
Just have to drill the aft edge of the side pieces to the aft baffle. This will require my angle drill, and the bugs were just getting too heavy in the garage to continue tonight.
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What was one, had to be cut in two
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Created filler piece
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Overall shot of baffles in place
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