1. If you decide to seal the outside perimeter of the nutplated ring which I did today, you want to do this before installing the front bulkhead to the main tank skin. Much easier to get at all sides with a syringe then.
2. When they instruct you to fill those 4 tooling holes in the baffles, do it before installing them. You can put blue tape over the stuff from both sides to hold the goop in place. If you don't, it's likely that the holes will open up again as the goop is following gravity.
3. Once you realize that you have a whole batch of Pro-Seal left when finishing your task, use it to fill up the corners good. Just fill the corners and then spread it slowly with the gloved free hand. When done, slowly move away from the corner following the skin and pressing down so you don't pull the Pro-Seal out of the corner again, opening up air holes.
Once you realize all that, the task is not so hard to do. Oh, just one more thing. To avoid spreading this black plague on every tool, have paper towels ready and an open bottle of isopropylic alcohol. This stuff is not dissolving the goop really well as acetone does but therefore it also doesn't dissolve the nitrile gloves as acetone does. With an old rag or paper towels you can really clean your gloves again and reduce the spread on tools.
Corner filled with a thick layer. Lost probably a quart of capacity right there :-)
Aft mount bracket installed. Don't let the reflection confuse you...
Baffle tooling holes and corners and the ring filled with goop.
Now the basic tank is done and the next step is to get the window in there. I've decided to give it one try and test the tank with the top off and water in it. I'll add some soap to reduce the surface tension and to help clean any contamination out.
If it doesn't work out I will take the window out and cover the fuel window holes up from the inside and outside with a thin skin.
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