Mark Jones' Corvair Engine Baffles
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***WARNING***....In these photos you see that the baffles on the air inlet completely cover the front cylinder jug causing the air to deflect up and over the jugs. This resluted in overheating of the front two cylinders causing ring failure. The extreme heat broke the cylinder rings resulting in a rebuild after only a few flight hours. You MUST NOT completely block the inlet air on the front cylinders. Leave at least half of the jug exposed to the incoming air.
These engine baffles are made using .025 aluminum sheet and 1/8" x 3" silicone baffle material. The baffle material is secured to the aluminum sheet using 1/8" pop rivets and an aluminum strip 1/16" x 3/4" as a backing. The purpose of the baffle on top of the engine is to force air entering from the cowl inlets upwards and then down through the cylinder fins for optimum cooling. The front of the engine will also be closed off to keep the cooling air close to the cylinders. There will also be another sloping piece attached to the front baffle top to the bottom of the cowl inlet to force the air upwards and over the cylinders. The cooling air will then pass through the cylinder fins and escape the cowl at the bottom rear.