Installed brakes, sealed firewall, finished cowls and baffles

Sealed up the firewall pass throughs. I followed the Van’s instructions on the left side using fire sleeve and RTV. It was challenging to get the fire sleeve stuffed into the fitting around the wire and also to safety wire the outer sleeve in place. Big hands. Small spaces. On the right side, there was no way I was going to be able to get my hands into the space necessary to take this same approach. I was able to form a cone around the cables/wires with tape. I then used a calking gun to fill the void with 3M Fire Barrier 2000+. The tape on the forward side formed a mold to force the sealant between all of the wires. Made a huge mess but it worked.

Installed AN fittings into brake calipers. Fabricated the brake lines and installed.

Finished installing the baffle seals on the cowling and installed the cowling back on the airplane.

I also spent some time tidying up the wiring under the panel and installing the adel clamps and wire ties on the control cables.

Today’s Time (hours):	10.0
Finish kit (hours):	323.0
Total Time (hours):	1057.0

Finished Snorkel, Installed Baffle seals, Installed control cables

Installed the alternate air door in the snorkel.

Formed the right air ramp cone and the cone in the air filter cover and installed them.

Installed the baffle seals.

Installed ignition wire pass-throughs, the blast tubes for cooling the mag/ignition, and sealed the baffles to the engine case with RTV.

Clamped the clamping strips in place on the lower cowl air inlets and filled the gaps with flox.

Installed the throttle, prop, mixture and alternate air control cables.

Today’s Time (hours):	20.0
Finish kit (hours):	313.0
Total Time (hours):	1047.0

Installed baffles and snorkle

Installed the aft baffles.. Pretty straightforward. Only thing I needed to trim was a path for the Manifold pressure line form the number 3 cylinder.

Installed the forward baffles. Also straightforward. Needed to trim a bit where the left baffle meets the case just forward of the #2 cylinder.

Decided to go with safety wire to tie the bottom of the baffles together rather than the rods. After a bit of research this seems to be a tried and true method and it’s a lot easier to install and remove.

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Fit and trimmed the snorkel. clecoed/bolted it all in place and bonded it to the air cleaner frame with epoxy and flox.

Connected up the SCAT tubes for the oil cooler and cabin heat.

Today’s Time (hours):	8.0
Finish kit (hours):	293.0
Total Time (hours):	1027.0

Started Cowl Baffle (Section 47)

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Picked, Inspected, and deburred all of the cowl parts.

Trimmed and deburred the cylinder baffle doublers and riveted to the cylinder baffles.

Installed nut plates and oil cooler flange and assembled aft baffles. Added strips of RTV to the mating surfaces.

Trimmed the air cleaner frame, added nut plates and fit to the inlet ramp. Assembled the left inlet ramp.

Attached the SCAT tube flange and screen for the heater air inlet to the right inlet ramp. Assembled the right inlet ramp. Added RTV strips to the mating surfaces of the inlet ramps.