I started off correcting a minor alignment issue on the right aft lower baffle that was causing a bit too much of a gap between the inner CF cylinder baffles and the front edge tabs of this baffle.

Simply put, the outboard mounting tab was too far forward and thus pushing the aluminum baffle away from the cylinder and causing the inboard gaps.  The mounting tab needed to come aft about 3/16″, which meant re-bending it.  Which of course meant bending it back straight first.

Once back straight, I needed to trim about 0.150 off the top to allow using my Mini metal bender since it only has a 1″ depth on the deep side (3/8″ on the other side).

I then re-bent the forward mounting tab.  It’s hard to gage exactly when bending this aluminum sheet, and definitely got close enough… optimum would have been about 0.030″ closer to my line, but this will definitely meet my requirement.

I then set the aft right lower baffle back into place to check the fit along the front edge.

With the front side gaps good, I then proceeded to cycle through getting the inboard edge and the starter opening dialed in.  That took a good half dozen times removing the baffle and taking a trip to my Dremel tool station.  I eventually got it, and barring a few very minor touch-up trims, the aft lower right baffle is now fitting rather well in its location.

Here’s a closer up view of the front side edge of the aft lower right baffle.

I then went back and did some minor tweaks on the left side, and here it is set into position as well.

And a shot with both left and right aft lower baffles in place… remember, they’re not mounted so these positions aren’t exact yet.

And a shot of the lower, intersecting baffle skirts around the alternator and starter.

Speaking of the alternator, I had to buy a new, longer bolt since I want to mount the alternator-to-starter reinforcement bracket on top/aft/outside of the baffling.  Not only will this allow the baffling to have a more comfortable clearance with the flywheel pully bracket, but will also help secure the intersecting baffle edges together.

With both side aft lower baffles looking good, I then pressed forward with finalizing the aft vertical baffles’ configurations.

Here we have the alignment mark on the aft left vertical baffle with the aft edge of the lower baffle (in the background).

I then bent the left aft vertical baffle on the metal brake to create a tab facing 90° outboard…

As can be seen here.  I then transferred the fitted cardboard tab that I cut out last week to this aluminum vertical baffle tab… and then trimmed it.

Now, there is a bit missing on the bottom which I will fill in when I but the reinforcing 90° angle bracket on the “back” side (technically forward) of this corner.

I then repeated the process for the aft vertical baffle on the right side: creating the 90° outboard-facing vertical tab, then trimming it to shape.

The right side too will need a minor addition on the bottom.  Again, that will attach to the reinforcement right-angle piece that will get riveted into the corner.

Here we have a shot of the current baffle situation.  I plan on getting these things mounted soon, then getting the flexible baffle seals mounted to the edges of all the aluminum baffle walls to finish the job.

Pressing forward!