Baffles are baffling. Sometimes. This is work that I do not enjoy – it is too persnickety. The cowl has to come on and off way too many times, and its just boring tedious work. There is a paper clip trick to help figure out where to trim the baffles, and that helps. Regardless, this takes awhile.
Additionally, the angle valve clearances inside the cowl are VERY tight. I have to pay special care to ensure that the engine and baffles will not hit the cowl, while also maintaining good seal.
This task has a reputation that proceeds it. A lot of folks complain about the baggage door not fitting well. Many folks advise getting the cowling fitted first – which is the approach I took. The one thing i would change after the fact, is i would have made a mock door to hold the firewall in place for fitment of the cowling. This would have sured things up a bit more. In the end I’m happy.