Online Community of Zenith Builders and Flyers
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.