Baffle Seal Material?
 

This shoudl generate some discussion!

I am looking for stuff to do while epoxy cures, and I figure I might as well tackle the baffle seals. What is the general opinion about the airseal material that Van's includes in the kit? I put orange silicone material on my Grumman when I swapped engines almost fifteen years ago, and aside from some worn spots, it's in pretty good shape. Does the black material do a good job, or will I just be doing the work over with better material in a short time?

Thanks for your inputs,

Paul Dye

I think you'll be very pleased with the black stuff. I think it works even better than the orange silicon seal.

I used the black stuff from Van's, too. Seems to be just fine after 100 hrs. I think the best defense againts premature wearing is a proper fit and smooth transitions.

Roberta

I used the black VAN's stuff on my RV6 and at 900 hours I only had to replace one piece, right at the air inlet that had a really tight curve in it and rubbed all the time.
It's lighter and thinner than the silicone material, and of course cheaper, since it comes with the baffle kit. You will also have plenty left over to make extra pieces if you ever need them.

Thanks!
 

I guess I'll get out my shears and go to work then.....

Paul Dye

Okay, Paul...Resurrection & Report
 

Paul, did you end up going with the Van's baffle material? Or did you do the silicone? I'm close to where you were five years ago, so I'd be interested to know if you're happy with your choice of baffle material.

Thanks!

Talk about a thread from the past!

Four and a half years and 1100 hours of flying, and the black baffle seal material is in like-new condition. I hardly pay any attention to it - I expect it will still be in great shape at overhaul time, and I won't have an excuse to replace it then either....

Paul

Paul, I've used them all. Way more than I ever wanted to. Used to do double engine changes on twin cessnas almost weekly. This included hand built hose kits and rebuilt baffles. The worst is the silicone with no fabric impreg (think RAM/Cirrus). Takes special fastening, backup strips, etc. When a tear starts, it goes zip. Next is the black neoprene nubby preg. Fairly tough, conforms well. Doesn't last so good (frays) and rubs cowlings a little. Next upscale is the silicone (red) with fiberglass preg. Tough, lasts, benefits from backup strips. It's a little too thick & stiff & expensive, but good. Will get squishy in mineral spirits. Vans black stuff is the best. Thin, conforms, smooth, clean edges, cuts with scissors, lasts long time, doesn't rub cowls, resists solvents pretty darn good. Why am I writing this instead of finishing my new Larry exhaust? Because yesterday it was 60 degrees and this morning there's a stupid blizzard outside with 1/4 vis. and uncle joe is movin kinda slow.

There are many opportunities to upgrade from some of Van's-supplied parts and materials. But it looks like I'll just stick with the stock stuff in this case. Thanks for the feedback, guys.

Has anyone used the "Cowl Saver" material from McFarlane? http://www.mcfarlane-aviation.com/De...px?Article=217