After the marathon efforts in getting these baffle profiles sorted it was finally time to cut them out. We had the BL 45 and BL 23 baffles in electronic format which meant I could get the A-0 sheets printed locally. They had an 11mm inside line too.

After printing I very carefully cut them out leaving the nose area per plans and the rest indented by the 11mm for the stake foam and skins. Next up I used paper glue to get them really stuck on the pre done foam and glass sandwiches I’d made.

I cut them out using a fine metal cutting blade on the jig saw. Afterwards just a very slight touch up with sanding sticks and I had my strake shapes.

The final step was to add mouse holes, or if you prefer, places the fuel can flow through. After a good look at the plans I added quite a few holes given my baggage space is being sacrificed for more fuel area. I’ll outline the hole making in the next log even though its out of order.

The last pic are my main baffles all done and the pre done cross baffles which I’ll cut to exact size once the main 4 baffles are in in position. Lets not talk about how many hours it was to get those paper templates completely off with zero damage. Too much paper glue!!!!!!! My bad cost me a whole afternoon.

Here I regretfully leave the strake building for a while. I really need to get the canopy done first so I can have easy access to the sides. The rollover also gets done before the strakes.

Glue on templates

Cut to size

Post holes and clean up