Kit #7 arrived

[Utah-Jay]

The final stretch is in sight… for the baffling

Plug line gaskets are in
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oil cooler plenum from the baffling is cleco’d in
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Cabin heat is plumbed on the co-pilot side
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[Utah-Jay]

Lots of progress on the baffling today. I got all the side pieces fitted, the front intake area is now fitted and the brackets have been drilled and cleco’d

Long Slow process, 8 hours in it today

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[rodsmith]

I feel your pain. The baffling work has turned into the most frustrating time consuming part of the project. Currently shaping foam for carbon transition pieces from the front of the aluminum baffling to the cowl inlets. I have a 3" prop extension which complicates the process further.

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[Bcone1381]

I've done that part of the baffling. I'm thinking you have the skills to make those ramps out of fiberglass. Forming the aluminum sheet in this area was tedious.

[Utah-Jay]

If anyone ever says baffling is fun I might hit them with a shovel

This is super slow and tedious, I am just measuring about 20 times, then a few more then times for good measure (pun intended) I finally started drilling and putting things together today.

Front ramp/ram air area
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[Utah-Jay]

Messed with baffling again today, and also clamped in my plenum and scat tube for the oil cooler. The scat tube is 4” for a lot of air flow, 3” to 4” doubles the volume
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[TrueAirSpeed]

Hang in there Jay! You’re doing fine.

[Utah-Jay]

Because TrueAirSpeed gave me grief about not posting lately…

Yes, I have been chipping away at the baffling, as well as priming for painting. I did try painting the spinner, but the environment was just not sterile enough to get the results I was shooting for. I found a new place to paint.

Hmmm, baffling. I will say this is the first time during the build that I actually felt defeated. It was just kicking my ass! Made progress today. Did a lot of match drilling and made progress for what seems like the first time in a week. It was a rarity, but I was so defeated I actually took a day and went fishing to get a break.

Here is my progress
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Had some interesting visitors yesterday

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Marine 1 and 2

[spinningwrench]

Normally the bolts on the carb float
bowl are either safety wired
or use the special no spin lock washers.

[Utah-Jay]

It was a baffling day, lots of measuring and them more measuring, then cutting. I was sneaking up on what I wanted, so I probably averaged over 2 cut/trims per piece. Several took 3 or 4
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This is the end of the day baffling scrap pile
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I had been monitoring my new GY 26’s for tire pressure, especially after one had a bad valve that I replaced. After 3 days holding pressure I put on the hob caps and re-installed the brake pads which is not one of my favorite activities. All safety wired up too.

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Yesterday I finally cut the pass through for the carb heat and ran the cable. I reattached the Throttle and Mixture. I had to build a stand-off for the Carb Heat cable and then cut the cable to length and attach.

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[Utah-Jay]

Let the fun begin. I must say the Vans directions/diagram leave a lot to be desired.
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Luckily I have a buddy with the cowling off his Kitfox that has a Lycoming engine to get so tips on how this all works.

[Utah-Jay]

Pinholes…. Thousands of them are filled and sanded
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Nose Bowl is ready doe primer and paint

[Utah-Jay]

Perfection is the enemy of completion

[Utah-Jay]

This is what 5 1/2 hours of sanding looks like after yesterday's application of the pinhole filler. The blue spots are superfill in a few areas that needed filling

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This is what 2 hours of changing out tires looks like in a dry climate. I have no clue how you guys live in humidity
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IMG_4478.jpg I sold the 26” ABW back to the original owner, luckily he wasn’t them to run during the winter months. I figured the GY’s will be a lot more durable for all the phase 1 flights and I figure I will get in the air during the winter when our grass is covered with snow.

[Utah-Jay]

It was the day to remove the engine cowl and nose bowl. Lots of filling and sanding, then rinse and repeat several times
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The I printed on the pinhole filler, so lots more sanding to come. This pinhole filler sands really easily though.
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The last phase of the airflow for the air filter was this fiberglass bracket which will have a metal strip for the riveting process. Laying up fiberglass is getting easy, which is good with the window faring still to come.
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