The first step was to unpack and identify the various parts. I seem to be missing the #9 baffle which covers the forward RHS section (#2 cylinder), I may have to wait until the next order from VANs to get it.
These are the major components laid out, nose towards the bottom of the picture.
Then it was the slow process of giving every part a once over with a file and scotchbrite wheel. This got rid of the worst of the sharp edges but I want to wait until I have a final shape before spending too much time finishing.
This was the first fit / mock up on the engine.
Out of the box the baffles fit OK out of the box, but will obviously need trimming.
One of the thing that takes a bit of thought is the 'plans' - hand drawn and not to the same level as the 'normal' plans.
The rear baffles need quite a bit of work. The instruction suggest removing the oil drain, dip stick and governor line but I'll hold fire until I get to that particular baffle (hopefully tomorrow).
The instructions start with the side baffles, the LHS has two parts which attach directly to the cylinders. The clearance was very tight and the rocker covers prevented the seating of the baffle parts.
After various struggling, I decided to remove the rocker covers to help work out the needed profiles.
The rest of the afternoon was spent shaping, match drilling the strengthening tabs and trimming as needed.
