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Date:  11-27-2016
Number of Hours:  3.00
Manual Reference:  Section 7
Brief Description:  Install Baffle on Left Tank

On Saturday, 26 Nov, I ran through tank assembly checklist to be sure all steps were completed, and all fittings tight. Rescuffed all mating surfaces on tank, baffle and Z-brackets. Washed all parts in Dawn dish soap and warm water, set out to air dry.

Today I wiped all mating surfaces down with MEK and washed all rivets in MEK. Ran tape lines on skin to help keep sealant controlled and make good fillet on flange of baffle. Measured two 60 gram batches of sealant and mixed one, set the other aside for later, also measured 10 grams extra as we came close to running out on right tank. Frances was here to help as we loaded the first batch of sealant into a medical irrigation syringe. Working with tank on the bench we ran a continuous 3/16 inch bead of sealant just in front of rivet holes on skin on the top of the tank. Had enough sealant left to apply sealant to the ends of several ribs. Flipped the tank over, mixed second batch of sealant and finished the ribs then put a bead on bottom of tank. Ran short of sealant and increased third batch to 20 grams, mixed it and put it in back-up syringe. Moved the tank to the cradle. Applied a thin layer to the flange of the baffle. Smoothed sealant on the flanges with a plastic picnic knife. Carefully set the baffle down in the tank and installed clecos in the top and bottom of ribs, then cleco'd the skin to the baffle starting at the center and moving out board. Got all cleco's in and inspected skin to flange joint. No "pillowing" at all with just clecos. Put some sealant on mating surface of Z-brackets and cleco'd them on as well. Set tank on bench with nose up to help sealant flow back into baffle joint. The areas we could see had a good fillet between baffle and skin.
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Ready for sealant

Ready for sealant

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Installing Z-brackets

Installing Z-brackets

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Good bead in tank to baffle

Good bead in tank to baffle

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