May 25, 2008 - Drill Air Seals to Baffles

Here are all my rubber strips along with their matching templates.
 
Now it's time to drill the rubber strips to the baffles, using the baffle as a drilling template. 
 
I taped the rubber strip into position, then match-drilled it.
 
This one is done.  See how the rubber strip curls inward. 
 
Drilling the aft baffles. 
 
And all done. 
 

Everything back on the engine. 

The time I'm spending on the baffles is horrendous but at least I'm making some tangible progress...
 
 
 
I figured I had better temporarily attach the cowl inlet ducts before putting the top cowl back on.  I drilled and clecoed them to the top cowl.  I didn't like drilling holes in the top cowl, but the instructions tell you to do it -- there is no other way.  It will be easy enough to fill the holes. 
 
I went to put the top cowl on -- and of course, it didn't even come close to fitting.  No big surprise.  After four years of building, I know better than to expect anything to fit the first time. 
 
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