Tonight I trimmed the widened flange, scuffed and ground the surface with a file and hacksaw blade to ensure a good mechanical bond (in the absence of a molecular bond). I re-drilled the attach holes on both flanges and then set about bonding the ends in place inside and out with a small fillet of VE resin and Aerosil. Once that was all done, I wet out a 3" wide carbon layer under the edge of the tank wall for extra grip area, and filleted three layers of carbon down the outer wall plus a layer of peel ply.
Next I'll prep and lay up carbon fibre reinforcement outside the tank ends and ProSeal all the inside wall fillets top and bottom, plus the hose, vent fittings and inspection panels and then we'll finally be done making tip tanks!
