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O-360 Baffle Kit from Van's

EXTAAFLY

Well Known Member
I am currently re-doing my baffle kit on my O-360 RV-8.

I am not THE builder, I am not A builder (yet). . .

I have been through significant portions of the skill set required to build, but have yet to check off the completion. Thus the learning continues.

A significant amount of my learning to date was on the -14 and much of that was done at Synergy. IMO, the -14 is a much different task/skill set than this project. More fab work, and more adaptation to my specific engine/cowl setup.

Working through the baffle kit has been fun, yet frustrating at the same time. Fortunately, I have a knowledgeable and very experienced support staff here.

I am getting there, but suffice it to say I should have just ordered two kits originally, then I wouldn't have had to experience shipping delays on replacement parts. :eek:

I am at the point to start making the CB-702J Conical Gusset's for the intake ramps. On my set up this looks to be a very small area, much smaller than the plans would indicate. Once I install the rubber seal around the inlet, I don't see much space for the gusset. I am wondering, is this feature needed/required? My original baffling didn't have anything like that, and others I have seen do not have them.

Those that have used this kit have any input/guidance on proceeding with or without these fabricated components of the kit?

Thanks!
 

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One tip I used: Start with a significantly larger piece of sheet metal. This makes it much easier to form (roll) a piece with tapered/conical bend. With the piece too small on one side, too big on the other, whittle it down to get a good fitting part. I used some 3/32 AD470 rivets (that I already had) as some rivets are a little hard to access.

Not sure if its really needed, but I found that the conical gusset makes a nice fit/guide for the cowling-inlet-rubber seal. I suspect cracking of the baffles is more likely without the gusset though.
 
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Conical gusset

Clamp one end of a piece of pvc to a sturdy workbench.
 

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Baffle

This is what I ended up with to get a good transition.
 

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