I have a version 2 Pilot RC 92 inch Extra 330SC with a one piece cowl and a DA70 motor. I am trying to figure out how to install baffles in a one piece cowl. Any suggestions? The two air intake holes in the front of the cowl seem awfully small so I think baffling will be imperative to keep from over-heating.

Try this.

Baffling your engine the easy way!!!! (11 min 53 sec)

For one piece cowls, it just takes a little more patience: first make paper templates (one piece at a time) with the cowl on, then cut the foam, remove the cowl, and glue that piece on.

Re-install the cowl, and move on the next piece.

actually, no. the intake holes on my EF 300 with a DA 120 are also small, but I have plenty of outlet air down below. the cowl is unbaffled. Same with my DA 70. Both fly fine. It's not going to hurt anything to have them, but chances you'll be fine without them as long as you have a large hole down below.

So i have had luck taking a picture of the engine with a ruler and scaling it to print out real size.. then using a woodworkers contour guage to draw the cowling outline around the pic... transfer to depron and cut it out for a test fit,, then go after it with the gorilla glue and some reinforcements on the back side of the cowl.. one shot deal and some latex black brushed on the front side of the depron for looks it and you are done. on the last cowl I baffled, the engine ran cooler than with no cowl by about 20 degrees.