I may be repeating what everyone else already knows, but just in case....

I've priced O200 baffles, and even the units built by other than Cessna were pricey, probably due to the FAA paperwork. The cheapest I found were around $800. That's a lot of money for a little aluminum, and a bit of seal.

Whilst browsing through my library, I happened to scan my copy of the late Tony Bingelis' "Firewall Forward." Inside, I found a scalable pattern for O-200 baffles.

That pattern got me through the worst parts. It doesn't really include the height of the baffles, because that depends on the cowl of the specific aircraft you build. But that can be solved pretty easily. My total cost so far is something less than $100.

If any of you are facing this problem, you might give Tony's book a looksee. It appears to have solved the problem on my XLB.

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Comment by Jacky Winters on August 19, 2012 at 11:49am

also found a video that is helpful to see the finished product...


Comment by Jacky Winters on August 19, 2012 at 11:47am

I found an AWESOME article that talks about O-200 baffles.  VERY HELPFUL!!!


Comment by Jim B Belcher on December 20, 2011 at 8:51am
Roger, unless I'm very mistaken, the templates include the intercylinder baffles.
Comment by Roger Lambert on December 20, 2011 at 7:34am

I agree the baffles available commercially are overpriced. There is very little modification necessary from the Cessna 150 baffles, but include the intercylinder baffles also for good cooling.

Comment by Mike Hammond on December 19, 2011 at 5:49pm

Baffles are available from Zenith. Drawings of the O-200 baffles are also available from big Z for a very reasonable price.

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