Lycoming 0-235 L2C

[planecrazzzy]

Starting on cleaning up the exhaust pipes , but ended up cleaning much more.
wow..just a little elbow grease.
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Gotta Fly...
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[planecrazzzy]

Hey Guys,
I made a new "Cap" for the Fuel Pump I removed.
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Others I had seen were thicker.
I was removing the Vacuum pump and needed to cap it, I figured this was a good time to make a better one to plug the fuel pump hole.
I cut them from scrap pieces I save...

The smooth side went toward sealing the hole...
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Gotta Fly...

[planecrazzzy]

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Still waiting to hear about my EGT system I ordered,
I'm glad they hadn't shipped it.... cause I wanted to change it from clamp-on to the bayonet style .
.meanwhile , looking it over for baffling , I saw the airflow restricted by casting that should have been cleaned better.
So I went over all four heads.
This area seems to NEED good airflow, it's next to the exhaust valve and spark plug.
it took a long time to hand file all the casting crap...
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Gotta Fly...

[planecrazzzy]

I got the Wool I ordered.
100% natural wool
It can be beat back with a flame, but it won't light on fire.
I sprayed it with the filter oil.
It's holding the oil.
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I needed to put the cowl together for measurements...(Baffle babble here)
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Gotta Fly...
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PS After reading this , it dawned on me... The oil I saw leaking...a few drips on the cowl...was from this air filter
I thought I was going to have to inspect my brake lines...

[planecrazzzy]

Baffling...

[planecrazzzy]

Baffling...
The front/left of the engine seems to be void of any attachment points to support the baffling.
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My plan was... WAS...Remove the starter...Take the front left "STUD" out...
The hole could be "Tapped" the rest of the way , Which would give me over 1/2" of threads to screw something into it.
No Joy... I tried to take it out. But I was at the point of Damaging something to get it to turn...So...Plan B
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I use .032 Chromoly plate...a couple Weld-nuts...
I used a thick "heat sink"...I pre-heat with a propane torch, Leave it until it's cold.
When I put the plate on the starter base , I changed the lock washers to star washers.
which were half as thick.
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Now, I have an attach point for the Baffling over the front of the engine,and a post support for baffle base/bottom
and with the holes I drilled into the plate I can put a cross support on the baffle .( a triangle )
The intake baffle on the left side is the biggest. a Truss/cross brace will be needed to help Engine shake.
Normal operating is fine. It's that "ROCK" when starting or shutting down that needs support.

Gotta Fly...
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[planecrazzzy]

Side pieces are rough...
and more paper will be harmed.
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Gotta Fly...
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[planecrazzzy]

Less Baffling
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With the cowl in place, I made some markers to show me the height...
Or what height it doesn't have...
The Datum on the Buttercup is 1/2" higher than a Tailwind...and closer to the cowl

Front, right of the engine is only 5/8" from the cowl... THAT'S gonna leave a mark.
Oh well...

It looks like my next step will be to make the front bracket.
I need more aluminum.
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Gotta Fly...
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hmmm, i could "slit"the cowl and let it flex if I have to...

[planecrazzzy]

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Baffling conversation followed by pictures...
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Gotta Fly...
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I've never had one of those "contour" tools.
They don't cost much...
I wish the tension could be adjusted...loosened for "fit" and tightened more to transfer the contour.
(Great...another tool mod)

[planecrazzzy]

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The alternator bracket can still be mounted where the chromoly spacer is used.(including the brackets "Jog" )
I replaced the bolt with a "Stud", it makes it easier for assembly in the tight area.
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Gotta Fly...
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[planecrazzzy]

Getting the plenum pieces closer

[planecrazzzy]

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The gap has a piece of fuel line...
It will have a heavier duty hose on final.
It does two things...
Dampens shock...
Holds the bolt during assembly in a tight area.
I'll need to safety wire the bolt
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Note... My seal is shit... (ok, maybe just crappy)
I HAD a nice fit... But in order to take it in and out...
the shape changed...
My plan has always been to get it close enough to use a rubber/silicone type seal...
I'm also thinking about a thick wool felt seal in places...maybe with leather.
yes...it's baffling
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Gotta Fly...
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[planecrazzzy]

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Building the back wall...
I have a start , forming cardboard it's giving me stretch out dimensions.
I need to Tape more cardboard to it...Then try a one piece cardboard.
I still haven't picked up another piece of aluminum
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This ain't the greatest cardboard for doing this... I need better stuff for the transfer to one piece of paper
One that will be "formed" with the Brake... Crisp lines.
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Gotta Fly...

[planecrazzzy]

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I made a solid contact in a tight/awkward area , Using 1/4" -.035 wall Chromoly tube.
later I might weaken the Cyl head connection for heat expansion (lighting holes)
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and still having FUN with cardboard ...with a little glue , the toothpicks will mark out a tighter profile

Gotta Fly ...

[planecrazzzy]

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Paper mock-up ...
I used some bailing wire to make staples for holding the added paper to the baffling shape.
This back wall will have to be more than one piece for a tight seal.
Gotta Fly...