In a dilemma about exactly how tubes are stuffed in a multi baffle plate heat exchanger. The half plate baffles are already stitch welded on inside of exchanger pipe.

With only a 1/64" clearance in holes for tubes I cannot fathom how one would insert a 35 ft tube thru the full length of a pipe with half baffle plates every 8 ft..

It seems like you would need a broom handle type wood stick aligned thru full length of pipe thru each baffle and then use it as a guide for the tube.

I don't know, have you had any experience around heat exchanger fabrication?

Appreciate your comments and advice,
Robert

Believe I found what I was after..... pilot guides that fit on the end of the tubes to be inserted.

It is important to make sure that weld will not make fretting corrion to the pipe.
The baffle hole should be smooth to tube.