Today I worked on the fuel tank ends and center baffle. If you're looking on your plans for the fuel tank baffle, you won't find it - it's something I'm adding. I'm building the long-range tanks that hold 15 gallons, and I want to reduce the sloshing around of fuel in the tanks. Since I'm going the "riveted tank with Proseal" route, there's a certain amount of making things up as you go along to finish your tanks - the baffle is a good example. I tried making these ends the same way we make wing ribs, but it was a miserable failure. The material is just too thick, and there was quite a bit of wavyness to the rib flanges that I thought was unacceptable. I'd seen Dave Clay and others make their tanks by drilling a relief hole, and removing some of the extra material. It works great. Since I'll be sealing the tanks with Proseal and these aren't structural to the airframe, it'll work out fine. I stopped just short of being finished with one baffle to go. I felt a bit of sloppiness coming on, so I stopped. I'll pick up next time and finish the other baffle, and polish these to their final stage for assembly.
