VansAirForceForums  
Home > VansAirForceForums

-POSTING RULES
-Advertise in here!
- Today's Posts | Insert Pics

Keep VAF Going
Donate methods

Point your
camera app here
to donate fast.

  #1  
Old 01-27-2018, 08:44 PM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 1,037
Question Trying a baffle cutting idea

I'm currently working (when I can find some time away from my job, it's been crazy-busy) on the engine baffles for my 8A project. I actually have two baffle kits. One is the "old" style kit that was available circa 2000. The other is the newer style kit that is more refined and has modern drawings and plans pages.

While thinking about making that first set of baffle cuts, to allow the top cowling half to finally sit down and fit to the bottom half, I spoke with several more experienced builders about how to get that initial trimming done. There are a variety of methods, with common themes. While I was working on another side project (microcontroller-powered pilot controlled lighting system for the airport) I was playing with a small collapsible metal antenna, the type that used to be on every walkie-talkie when I was a kid, which got me to thinking.

I decided to take my "old style" baffle kit and sacrifice it, to see if I could make a tool of sorts that would provide a variable template, which could provide an accurate measurement of the inside of the cowling, then be overlayed on the baffle pieces from the "new" kit, to make the initial trimming measurements a little quicker and simpler. I headed on over to the aviation section at a local Harbor Freight and picked up a big batch of small inspection mirrors for a few bucks each. When you remove the little round mirror, you're left with a collapsible rod handle with a little ball on the end. The cashier was curious and had never seen someone buy 18 inspection mirrors at once, so you know how that conversation went. "Wait, did you say you're building an airplane?!?!"

I cut down the old baffle sides and back pieces, got some aluminum tape, strategically places some of the collapsible rods, and ended up with essentially what I had in my head. It's entirely possible someone has done this before, no idea. I just wanted to do something different and fun.

Anyhow -- Here's a rather long video (sorry, I ramble a bit too much when I think out loud) showing what I came up with so far:

(Click image for video)

YouTube: https://www.youtube.com/watch?v=WvIdjh1VzJA

I have not yet completed the actual cutting yet, so if anyone wants to warn me away from this please feel free! But I will report back here to let people know if I end up having to buy any replacement aluminum baffle parts or not. When I ran the idea by our friend Scott he advised me to be careful about the resulting measurements since the top cowling is curving over and is at a pretty extreme angle in these areas, so it's not a simple measurement. Good thing to be sure to pay attention to. I think if I am careful not to cut too much and if I measure carefully this might work. We shall see. My goal is to get it trimmed to where it basically just meets the top cowling, then switch to the paperclip method. Just trying to simplify that first set of bigger trimming cuts and maybe shave off some of the time spent getting to the finer trim stage.

*If* it actually works well, I was thinking maybe it could be a "tool" of sorts that could be shared and used by people when they get to that point. This one fits a parallel valve 360. Not shown here (since I have not finished them quite yet) are the rear baffle pieces.





__________________
Greg Hughes - Van's Aircraft
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)

Reply With Quote
  #2  
Old 01-27-2018, 09:03 PM
Robin8er Robin8er is offline
 
Join Date: Sep 2015
Location: Socal
Posts: 524
Default

If you search the paper clip method its basically the same idea. The problem, at least on my 8, is that you need to measure about every inch or so, not every few inches. the gap between points that you measure isnt linear in most places.
__________________
RV-8 N695RA flying
Working on an RV-4

Born to fly, forced to work
Reply With Quote
  #3  
Old 01-27-2018, 10:10 PM
pilotkms's Avatar
pilotkms pilotkms is offline
 
Join Date: Mar 2007
Location: WARNER ROBINS, GA
Posts: 526
Default Paper clips

Yes. I think paper clips are the standard method. Simple & cheap. $1.29 or so.
__________________
Keith
RV 7A RV #9700 May 2017
N325KS the Flying K
Built in SoCal KCCB, now in GA @ KPXE
800+ Hours & 7X cross the USA
OSH flyin 2018 & 2019 & Petit Jean 2019 & 2021
Reply With Quote
  #4  
Old 01-28-2018, 09:24 PM
Gisnar Gisnar is offline
 
Join Date: Nov 2012
Location: Northern Nevada
Posts: 140
Default

Looks kind of like the EAA Hanger near by! Nice job on the build so far. Another thing to try is set up a tripod with a digital camera. Take two picture, one with the cowling on, on off.
Overlay the pictures and presto you can see the contour.
Reply With Quote
  #5  
Old 01-29-2018, 05:04 AM
rzbill's Avatar
rzbill rzbill is offline
 
Join Date: Nov 2005
Location: Asheville, NC
Posts: 2,752
Default

A sharpie marker with a 1" dia rubber grommet on the writing end, taped to a stick, worked quite well for me.
__________________
Bill Pendergrass
ME/AE '82
RV-7A: Flying since April 15, 2012. 850 hrs
YIO-360-M1B, mags, CS, GRT EX and WS H1s & A/P, Navworx
Unpainted, polished....kinda'... Eyeballin' vinyl really hard.
Yeah. The boss got a Silhouette Cameo 4 Xmas 2019.
Reply With Quote
  #6  
Old 01-29-2018, 07:15 PM
fl-mike's Avatar
fl-mike fl-mike is offline
 
Join Date: Jul 2005
Posts: 1,606
Default

Five paint mixing sticks, eight c-clamps, sharpie, duct tape. Done.
Don?t over-complicate it.

Kind of like trimming a countertop to fit against an irregular wall, only vertical.
__________________
Mike W
Venice, FL
RV-6A. Mattituck TMX O-360, FP, GRT Sport EFIS, L3 Lynx NGT-9000
N164WM
N184WM reserved (RV-8)....finishing kit in progress. Titan IOX-370
N184P reserved (RV-8QB)
Reply With Quote
  #7  
Old 01-31-2018, 03:02 PM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 1,037
Default

Gotcha. I am planning to use paperclips after the initial cut that this things in intended to help make.

And over-complicate things? Me??? Hah... Ask my ex-wife about that.
__________________
Greg Hughes - Van's Aircraft
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)

Reply With Quote
  #8  
Old 01-31-2018, 03:04 PM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 1,037
Default

Quote:
Originally Posted by Robin8er View Post
If you search the paper clip method its basically the same idea. The problem, at least on my 8, is that you need to measure about every inch or so, not every few inches. the gap between points that you measure isnt linear in most places.
Yeah I have been looking at that. Have not had time in the hangar this week to do much so no new work here. The idea is to get a cut that is very close to the cowl surface, then user paperclips or similar to make the final 3/8 - 1/2 inch cut.
__________________
Greg Hughes - Van's Aircraft
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)

Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -6. The time now is 04:51 PM.


The VAFForums come to you courtesy Delta Romeo, LLC. By viewing and participating in them you agree to build your plane using standardized methods and practices and to fly it safely and in accordance with the laws governing the country you are located in.