Cotton Waiex 191 - N191YX

[Bryan Cotton]

We worked baffles today. When I cleco the aft baffle to the case I get a huge mismatch. I am thinking of cutting the baffle and making a triangular z bend piece.

I weighed my interior. The cushions are 6.44 lbs minus the stick boots. I still plan to make a baggage sling and map pockets.

Here Matthew and I are trying out the fit.

[GordonTurner]

Looking good Bryan!!!

Soon....!!!!

Gordon

[Bryan Cotton]

Thanks Gordon!

Here is the paper pattern for the baffle mod. You can see the intake tubes do not align with the holes.

Here is the flat pattern.

Trial fit. Still need some tweaking and of course we have to polish the rest of the baffle.

[Bryan Cotton]

We ended up remaking both outside parts of the aft baffle. Here Adam is using the fan spacer to make pilot holes.

With the aft baffle clecoed in, we marked the proper hole location for the intake tubes.

Before they were way off.

We still have some tweaking to make it easier to assemble.

This corner was tricky. Not quite done yet. I recommend not bending the front of the side baffles until you fit the front corner piece. That allows you to mark where the front corner piece is happy, and bend there.

[Bryan Cotton]

We make it nice because we make it twice (or thrice). We remade one left side aft baffle part, and two each right side plus the prop hub part. Soon we will have it all clecoed together and can experiment to see what connections get screws and which ones get rivets.

[Bryan Cotton]

Still slowly going on the baffles. I'll be remaking this part over I think.

I had a two week delay of game while I fixed my $500 Saturn, but that is another story.

[Rynoth]

Still slowly going on the baffles. I'll be remaking this part over I think.

I had the same issue with the right front baffle being a long way from the cowl. The baffle seal from ACS was wide enough to cover that gap though, and stiff enough to make a good seal...

[Bryan Cotton]

My right front corner baffle did not need a hole to clear the exhaust. I remade it.

Here is my new right front baffle.

I bought silicone rubber strips from the Amazon aviation department. I'll let the group know how it works out.
https://www.amazon.com/gp/aw/d/B078Z2G5BW?psc=1&ref=ppx_pop_mob_b_asin_image

[Bryan Cotton]

I've completely overtrimmed the right side baffle and the right rear corner. I think I'll have made 3 or 4 baffles for this thing before I get a good one.

[Bryan Cotton]

Here is what I'm doing for my oil cooler.

I measured and calculated about 10.5 square inches of area for the cooler. That is equivalent to a 3.7" tube.

Still a work in progress.