Brief Description: Custom Front Baffles For IO-390 - Part 1
Because of the front mounted governor on the IO-390, four baffles required either significant modification or simply complete redesign. The left and right floor baffles required some trimming to fit up to the crankcase correctly as there is a square boss on each side of the IO-390 that doesn't seem to exist on the IO-360. I created a cardboard template of each side from the stock baffle piece and used the cardboard piece it to get the fit around the bosses just right. Once I was happy with the cardboard fit, I transferred the new shape to the metal piece and cut away the extra material.
The left and right front baffles, however, wouldn't fit at all and so I had to start over from scratch. I used the top case mount bracket from the RV-10 baffle kit. This case mount puts the front baffles back from the IO-360 stock location by about 2 inches to clear the prop governor boss on the left side. Again I used soft cardboard to cut out some paper-doll patterns and basically just trial-fit about 5 times on each side until I got a pattern that fit correctly.
Please refer to the October 16 2009 log entry entitled "IO-390 Baffle Templates" for high-resolution PDF CAD drawings of the custom modified baffle pieces for the IO-390.
