Experience with McFarlane Cowl Saver baffle seal material

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Kevin Holbrook

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I recently acquired a PA-24-250 Comanche and one of the items on the to-do list is replacing the baffle seals. I have always used the red silicone seal material from AS, but am intrigued by the marketing material for McFarlane Aviation's Cowl Saver baffle seal material. It has a slick side to supposedly reduce vibration transmitted to the cowl. Sounds good, but it is significantly more expensive than what I have used in the past.

Just wondering if anyone has any experience with this material, and if the benefits are real.

Thanks in advance...
 
I installed it a few years ago.
Yes I do think it reduced vibration.
The main reason used it is because I was experiencing wear on the bottom side of my cowl from the old stuff.
Nothing from McFarlane is cheap but it is all good stuff.
Is it worth it? that is up to you.
Maybe someone could have done a better job installing it?
I installed it using all original holes and the same length of each piece as original.
It seals 100% to my cowls and the wear on my cowl has not gotten worse.
IMG_4546.HEIC
 
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Gary, what is the handle attached to your crank flange? I've never seen anything like that.
 
kyleb said:
Gary, what is the handle attached to your crank flange? I've never seen anything like that.
Click to expand...
That is a tool to install a one piece crankshaft seal.
New seal with the spring out of it. You take the spring out before stretching over the flange. Then put the spring back into the seal before installing it into the case.
IMG_4548.HEIC

Hasn't leaked a drop since. Pretty sure the old seal was leaking on the OD, through the sealant.
IMG_4558.HEIC
 
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To prevent wear on the underside of your engine cowling apply foil duct tape over the wear lines. My soft baffles had worn through the yellow zinc chromate to shiny aluminum beneath. I used 2 widths. In 20 years, the tape still looks almost brand new.

www.homedepot.com

Nashua Tape 1.89 in. x 50 yd. 322 Multi-Purpose HVAC Foil Sealer Duct Tape 1906075 - The Home Depot

Professional results that a DIYer can be proud of begins with 322 Multi-Purpose HVAC Foil Tape by Nashua. Specially designed for joining and seaming connections in flexible and sheet metal duct work where
www.homedepot.com
 
Gary, did you warm up the one-piece seal in hot water before stretching it over the flange?
 
Kevin Holbrook said:
I recently acquired a PA-24-250 Comanche and one of the items on the to-do list is replacing the baffle seals. I have always used the red silicone seal material from AS, but am intrigued by the marketing material for McFarlane Aviation's Cowl Saver baffle seal material. It has a slick side to supposedly reduce vibration transmitted to the cowl. Sounds good, but it is significantly more expensive than what I have used in the past.

Just wondering if anyone has any experience with this material, and if the benefits are real.

Thanks in advance...
Click to expand...
I tried the Cowl Saver on my Twin Comanche, but am not a huge fan. I went back to the silicone. I find it a bit too stiff for optimal sealing.

FYI, there are good Comanche resources on FB and the Airworthy Comanche Forum on Delphi.

Enjoy your new bird! They are great planes.
 
Kristin said:
I tried the Cowl Saver on my Twin Comanche, but am not a huge fan. I went back to the silicone. I find it a bit too stiff for optimal sealing.

FYI, there are good Comanche resources on FB and the Airworthy Comanche Forum on Delphi.

Enjoy your new bird! They are great planes.
Click to expand...
They make a rather expensive roller cutting tool to customize the fit to your cowl. It puts little slices in the baffle material to allow it to conform better.
 
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I'm surprised cowl seal material isn't always installed between two sheets of aluminum, rather than simply depending on a rivet head to retain it.
 
Domenick said:
To prevent wear on the underside of your engine cowling apply foil duct tape over the wear lines. My soft baffles had worn through the yellow zinc chromate to shiny aluminum beneath. I used 2 widths. In 20 years, the tape still looks almost brand new.

www.homedepot.com

Nashua Tape 1.89 in. x 50 yd. 322 Multi-Purpose HVAC Foil Sealer Duct Tape 1906075 - The Home Depot

Professional results that a DIYer can be proud of begins with 322 Multi-Purpose HVAC Foil Tape by Nashua. Specially designed for joining and seaming connections in flexible and sheet metal duct work where
www.homedepot.com
Click to expand...
That’s what I do as well, with the Reflectix tape from HD.
 
Gary Ward said:
This is what mine was, I think that is original?
IMG_1109(1).JPG
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Yes, that is what my 1979 Warrior had on it 23 years ago when I bought it. I always assumed it was original. Nasty, stiff stuff, but it was from 1978 or earlier. Considering its age, it held up quite well.
 
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