Front left baffle

I spent much of today making the front left baffle. Starting with a cardboard template, this took a couple of hours - mostly getting my head around how I was going to do it. Then I traced it to the .025 aluminium, cut, deburred, and bend to shape. Next was drilling, countersinking, and continually checking the fit.

Also required was to cut a larger hole for the prop governor which I did mostly with the scroll saw.

I think I’m going to have to cut and remake the front lower air dam because the Vans one has a different fit which I hadn’t realized. The air intake for the heat muff is too close to the nose bowl. I’ll try to leave room for another air intake for the throttle servo in case I decide to go down that route.

This evening I cut the cone shaped fillets for the corners.

Tomorrow I’ll rivet the curved cone shaped fillets in the corners.