Fitting the tanks involves quite a bit of match drilling to ensure a tight fit to the leading edge and spar. much of the complexity of the tank is from its removability from the main wing structure... hopefully this feature will not prove to be a necessity.
Fitting the tanks requires an enormous batch of free clecos... I am continuously removing clecos from the wings to use on the tanks... even with 500 I could use another 200...
|Z brackets setup for fitting to the tank baffle
|outboard tank Z bracket on right
|fitting the leading edge and tank to set the Z brackets behind the tank baffle
|first, drill the inboard Z channel to the tank rib
|next, remove the leading edge and drill the outboard Z channel to the tank rib
|remove the tank from the end ribs leaving the baffle attached
|finally, match drill the tank baffle to the Z brackets attached to the spar underneath
|put it all back together to fit the leading edge to tank join plate
|very important to pull everything tight to get a nice uniform join line
|leading edge to tank join line
|this came out great :)
|left wing fitted up
|the rear baffle rivets need to be countersunk to let the baffle easily slide in with pro seal to close the tank