Baffles are rough trimmed to fit with a tiny gap. Maybe 1/8". Next is the final trim to allow for engine movement.
I have a plenum if it makes any difference. I want the maximum air space.
What is the recommended gap?
Van's instructions say 3/8" min - 1/2" max between the baffles and the cowl. I made mine my index finger width apart all the way around. That's somewhere in the 1/2"-5/8".