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Old 11-01-2017, 06:13 PM
Louavul's Avatar
Louavul Louavul is offline
Join Date: Jan 2005
Location: Rio Communities, NM
Posts: 130
Default Engine Baffling

Gents: Began installing my engine baffles and ran across this issue right away.
Seems the flange on the rocker cover is interfering with the baffle screws.
Just courious if anyone else has had this and how did you deal with it?
I figure notching the rocker cover is the way. Thanks!

Steven Hild
Rio Communities, NM USA
RV-7, FWF/Fiberglass, N590SC res

Contributing annually since January 2002
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Old 11-01-2017, 06:20 PM
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pazmanyflyer pazmanyflyer is offline
Join Date: Jul 2007
Location: Litchfield Park, AZ
Posts: 829

Maybe add a few trimmed washers under the screw? Use longer screw in needed.
Carlos in Arizona
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Wittman Tailwind W8 N53CH (built & sold)
Pazmany PL-1 N2029 (bought & sold)
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Old 11-01-2017, 06:42 PM
rockwoodrv9 rockwoodrv9 is offline
Join Date: Dec 2011
Location: Meridian ID, Aspen CO
Posts: 2,442

Maybe grind the head of the screw a bit? The real answer is whatever works to make it work!
Meridian Idaho
O-320 D2A
Awaiting DAR Inspection
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Old 11-01-2017, 06:53 PM
David Paule David Paule is offline
Join Date: Dec 2009
Location: Boulder, CO
Posts: 3,553

Maybe you can find a screw with a reduced-diameter head, like the NAS1351 or 1352.

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Old 11-01-2017, 10:15 PM
jrs14855 jrs14855 is online now
Join Date: Apr 2008
Location: Lake Havasu City AZ
Posts: 2,123
Default Screws

Stainless allen head screws (aircraft spruce) work great and wont interfere with cover. Flat washer and star lock washer under the screws same as most other Lycoming fasteners.
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Old 11-02-2017, 02:51 AM
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rzbill rzbill is offline
Join Date: Nov 2005
Location: Asheville, NC
Posts: 2,534

Consider replacing or adding thickness to the half moon piece until it is thicker than the valve cover interference.

This would avoid the need for different or custom screws or washers.
Bill Pendergrass
RV-7A: Flying since April 15, 2012. 710hrs
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Old 11-02-2017, 09:02 AM
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Bob Martin Bob Martin is offline
Join Date: Jan 2005
Location: Richmond, Virginia
Posts: 1,106
Default close

Before doing anything rash............
The relationship of the threaded hole and the valve cover has little to do with the baffeling. From the picture it appears the cover flange is bent over, possibly from the screw pressing on it. You may be able to massage the fit by rebending the flange back up. You might also try another brand of valve covers, etc.
IIRC the pusher guys have to safety wire these screws and use a different size head (smaller) that is drilled. That might help as well.
For the record, what brand cylinder is it?
Good luck.
Bob Martin
RV-6, 0-360 Hartzell C/S, Tip up, 1150+TT
James extended cowl/plenum, induction, -8VS and Rudder. TSFlightline hoses. Oregon Aero leather seats.
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Louisa, Virginia KLKU N94TB
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Old 11-02-2017, 10:45 AM
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Ironflight Ironflight is offline
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Join Date: Jan 2005
Location: Dayton, NV
Posts: 11,686

I agree with Bob Martin - the amount of interference looks almost like the amount that the flange on the valve cover appears to be bent outward. I'd roll that back in somehow and see if it fits then. I've never had one that didn't fit, but they are always very close.
Paul F. Dye
Editor in Chief - KITPLANES Magazine
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Old 11-02-2017, 11:51 AM
Ralph Inkster Ralph Inkster is offline
Join Date: Feb 2008
Location: Calgary, Alberta
Posts: 396

Space out the screw head with washers if need be, but don't grind the V/Cover flange, you will cause uneven gasket tension & leaks will result. Plus, your nice chromed V/C will rust there...
Maintain lots, upgraded & repaired some, modified more, rebuild a few, & built 4 of 'em
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Old 11-02-2017, 12:22 PM
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dave4754 dave4754 is offline
Join Date: Oct 2009
Location: Edson, Alberta, Canada
Posts: 438
Default My two cents

I agree with the previous poster that the valve cover looks bent at that point. They are a close fit and if the cover is bent it would prevent the screw from going home.

However, the other poster made a good point, all bending must not compromise the sealing pressure of the nearby ridge on the valve cover or you will have leaks.

I would take a small hammer and gently bang on the ridge till it moves back enough to allow the bolt while doing so i would put a straight edge on the bottom of the valve cover and ensuring it does not go out of true.

Dave Cobb
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