ENGINE BAFFLE E-BOOK

Tips, tricks, & Information about your engine baffles

BROWN AIRCRAFT SUPPLY, INC

4123 Muncy Rd Jacksonville, FL 32207
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Aircraft Engine Baffles

We all know that airflow keeps our Aircraft Engine cool...right? What most are unaware of is the
fact that “proper” airflow doesn’t just happen. Like most things in life there is a system that is
used to achieve this goal and in our aircraft it is called “Pressure cooling”. Pressure cooling is
the method used in all modern piston aircraft and it is accomplished by placing a cowling around
the engine and using a system of baffles and seals. These baffles and seals are engineered to
produce the volume and pattern of proper cooling airflow through the cylinder fins.

Assuming that not everyone is familiar with the engine baffles and the components that make
them up we want to give a quick explanation. There are two components to your baffle system
the first is the rigid aluminum baffles that are attached to your aircraft engine, they typically run
down the sides and then across the back of the engine. The other item is the flexible baffle
seals, they seal up the gap between the rigid baffles and the cowling. Most of the time they are
a silicone rubber material but, occasionally they can be a neoprene rubber material. The flexible
seals are what this article will mostly focus on.

While your baffles aren’t the coolest item on your aircraft they do help to protect and extend the
life of the most important item on your aircraft the engine. They do this by dividing the engine
compartment into two chambers a high pressure and low pressure area. The high pressure area
is the top side of the engine where the air enters from just behind the prop, (the area above the
cylinders). The low pressure side is the area below the cylinders and behind the engine. So to
cool the engine we need to get the correct volume of airflow from a horizontal to a vertical flow,
so it will flow through the cylinder fins. All of this is accomplished with proper working baffles and
seal

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When airflow is allowed to flow from the upper chamber to the lower chamber without flowing
vertically through the cylinder fins the engine cooling is considerably reduced. Even the smallest
leaks in the baffle system can have a serious adverse impact on engine cooling, performance,
and ultimately engine life. Here are several factors that allow Airflow to be ineffective and
degrade engine cooling.

● Missing Baffles Seals

● Broken Rigid Baffles
● Torn Baffle Seals
● Improperly Positioned Baffle Seals
● Incorrect Baffle Seal Sizes (either undersized or over sized)

The most trouble-prone part of the cooling system is the flexible baffle seals. These seals are
typically 2 to 3 inches tall and seal the gap between the baffles and the cowling. The flexible
seals are necessary due to the movement between the cowling and the engine as it rocks on
the shock mounts. This movement tends to lend to the issues found with the seals.

As most of you know the correct installation of these flexible baffle seals are critical to the
cooling system functioning properly. When installed they should curve up and forward into the
high pressure chamber. The air pressure will press them tightly against the cowling creating a

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 Quality doesn’t cost, it Pays!

seal and forcing airflow through the cylinder fins. If they curve out then the airflow will escape
without doing any cooling. Once installed one of the issues to check for on the flexible baffle
seals is for wrinkles or creases once the cowling is installed. This will cause them from creating
an airtight seal against the cowling.This is an inspection that should be checked each time the
cowling is removed and replaced, and especially important when the seals have been replaced.

As with any part of maintaining a solid aircraft it is imperative to perform preventative

maintenance and inspect and catch issues before they become problems. Your engine baffle
seals, is a part they will need to be inspected and at some point replaced as you protect the life
and performance of your aircraft engine. So feel free to reach out to us here at Brown Aircraft
Supply and let us assist you or you can vist our website @ www.brownaircraft.com and see our
full selection of engine baffle products.

Inspection Tips

● Always Inspect when the engine is being serviced

● The Flexible Seals should be checked during periodic inspections

● If cylinder Temps are higher or inconsistent with each other check seals

● Inspect underside of cowling for even wear marks where the seal meets the

cowling

● Verify if the Seals are soft and flexible

● Verify that the seals curve in and forward not bent backwards

● Check for rips, tears, or fraying of the seals

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