Showplanes now offers a custom baffle kit that fits much more easily with their cowl and intake system, so I got that:
Showplanes baffle kit parts
The main part of the modification is to cut off the ramp part of the stock forward baffle parts, and replace them with the Showplanes-provided ramps (as a separate part that will be riveted together):
Forward baffle assemblies with the ramp replaced by Showplanes'
Left baffle ramp in place
Left baffle ramp and cylinder 2 baffle
Right baffle ramp and forward baffles in place
I had to again remove the governor bracket to get the left forward baffle in, but it fits quite nicely:
Forward baffle in place around governor
All baffles in place
For the EFII tach wire, I opened a slot to get it in, to be held in place with a grommet:
Right forward baffle with tach wire going through it
At this point, after some minor trimming, the forward baffles fit in place and I attached the forward center bracket to the engine case - which required some trimming due to the odd shape of the engine case opening - and match-drilled it into the baffles:
Forward center bracket attached to engine and (temporarily) attached to baffles
Forward center bracket sitting in place, trimmed to fit the engine case opening
We also fabricated the cylinder baffle clips and match-drilled them in place:
Baffle clips
Baffle clips clecoed in place
Finally, I started test fitting the plenum, which will clearly need some work - both to connect it to the cowl air intake openings, and to align (and seal) the oil door opening:
Plenum sitting in place
Plenum oil door opening
One thing we didn't do yet was to bend the forward portion of the cylinder 1/2 baffles, to support the air ramps. We were waiting for the intake system to be sufficiently positioned that we were comfortable taking away the play that the ramps have there - so that'll come next.
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