Well, both tanks are almost complete.  For the second time.  Now, if my fuel tank luck continues at its current rate, I’ll likely have several leaks!

Today I installed the new baffle on the right fuel tank.  I completed the installation including the z-brackets and now the only remaining part is to seal the access plate.

I started by drilling, deburring and scuffing the new baffle.  Then I cleaned all the parts with acetone and cheesecloth.  The z-brackets took quite a bit of work to get all the old sealant and primer off.  (Priming them was a stupid idea in retrospect especially considering I would need the sealant to adhere to them.)  

Here are the z-brackets in the process of cleaning.  I used my typical acetone, scotchbrite, acetone again approach. 

The instructions say to cleco every hole for the skin to baffle joint. 

Next I quadruple checked my z-bracket alignment and installed with the closed end pop rivets.

And finally I used the pneumatic squeezer to rivet the skin to the baffle.  Peaking inside through the access hole, there appears to be a good bead of sealant.  Hopefully I don’t have any leaks.