Both the baffle floors needed more bending / shaping. Slow iterative process.
The challenge was not to distort the shape too much - particually where the material was very thin - like the inboard edge of the RHS floor baffle after my (wrong) C cut. Two pieces of stock steel between two large vices seemed to work quite well.
One problem that I can see coming is the spark plug lead on the #2 cylinder if we want to use an angle on the baffle sides for a plenum. More thought needed, I really like the idea of a plenum but it is these kind of complications that might make it hard work.
Next on the list is the front baffle - this has a number of independant areas, the floors and the 'upper level'. A cardboard template gave a good starting point.
This shows the clearance is fine in the middle, but the edges of the centre section of any plenum is going to need some profiling to get round the fuel divider. The current plan is to use a 90 degree elbow to assist with some of this problem.
I think overall I'm coming down on the side of the extra work / complications of a plenum, with the escape clause that I'll try and use as much of the standard VANs baffling as possible which means I can always revert to fabric seal if needed.
