I haven't even started my first down project, and this exact problem is a main reason why.
The only possible solution I've come up with in my head would be to sew the outer shell down the end of the baffle to create the box end. The much simpler way would be to just scrunch each baffle down accordian-style and sew it all flat and either grosgrain the heck out of it, or roll it.
Ooooohhhhh, (in my best Mr. Grue voice) Lightbulb.
What if the end of the baffle was curved to add length to the outer shell, and curved up to nothing at the end? That would add the distance needed for the differential, and get everything to meet up nice and clean at the end. I need to write that in my DIY notes.
Sorry for the mental barf.
PF
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