Little helper.

Engine baffling.

The new engine baffling added a ton of time to the whole process, but it sure does look nice when it's done.

The finished product after installing the flexible engine baffling (the black material).

Installing the back baffle piece.

This is basically the finished product for the back engine baffle.

This big back piece also had a couple places that were formed out to clear the exhaust and intake areas of the aft cylinders. This is one of the sets of blocks made fot his purpose. The 2 big pieces were clamped tight and then the arbor press was used to press down on the center die to form the aluminum.

Lining things up preparing to make a joggle.

The joggle die doing its thing.

The rear baffle piece requires a couple a joggles in the material. Dad made me 2 sets of joggle dies (one 1/2" set and one 11/32" set) for this part of the project. They worked great in the arbor press.

The long process of final fitting.

This is what it looks like after the flange is formed.

This shows the flange as it is being formed.

A couple of the baffling pieces required a 1/2" flange all the way around the outside. This was done by making forming blocks and then a leather mallet to form the flange around the outside. This required quite a few trial and error pieces to get it right.

More baffling fit and installed.

Installed.

After some trimming and bending.

After some deburring I started with the baffling that goes around the bottom of the case to see how things were going to fit.

Dad got my new baffling all cut out this week. The original baffling was used as a template and all new was cut using a water jet.