Worry not, Jon -- I'm married. No chance of an inflated ego.Oh, jeeze, now you're gonna make Kevin's head swell so much he won't make it through the doors!:roll:
I'd still use a protector of some sort.
Yes, and no. If you design the baffle so that there is no way for the hot particulate matter to gat out of the top end of the baffle, then no, you don't need any type of wadding / chute protector. I've done three different rockets with the method described in this thread: https://www.rocketryforum.com/showthread.php?t=1901&highlight=baffle and have not had any holes burned in my chutes - no wadding, no dog barf, no nomex. My fourth is a 4" Samurai under construction, and I have no worries it'll also protect the laundry just as well. My design uses an "S" curve for the gas, which doesn't mind going around corners twice to get out of the top. Particulate matter doesn't make U turns too well.