The Vans baffle kit arrived today so I could make a start fitting it. Vans only do a kit for a dynafocal mount O-320 engine and I'm using a straight mount O-235-C2C so I expected that some "fettling" would be needed. The first obvious problem was that the mounting holes where the side baffles bolt onto the cylinders were in completely the wrong place although the cut-outs for the rocker covers were thankfully completely accurate. So cover plates for the incorrect holes were fabricated and riveted into place. Then correctly placed holes were drilled and the doublers and strengthening angles riveted into place. Next the rear left baffle was test fit. This needed many-many iterations of trimming to fit round the parallel engine mount. Finally a good fit was achieved and it was riveted to the rear left-side baffle.
There is a mounting bracket, just visible in the picture, screwed to the rear two top engine join bolts. This also required much adjustment to fit on the bolts and clear the engine crankcase but eventually it was in place and the left rear baffle was match drilled and clecoed to it. This will be bolted up when the baffles are finally installed.
The right rear baffle was easier to get fitted snugly around the engine. It will need a spacer to rivet it to the rear-right-side baffle but that is a job for tomorrow. 8 hours work on the baffles so far!
