Feb 13, 2002 3 hours
I started on the right tank tonight. I have followed the build sequence as presented in the plans as closely as possible throughout this building process. Tonight, I decided to deviate from the build sequence as described in the plans. I visit other builder sites to get ideas on how they have approached different tasks and Steve Hurlbut described a build sequence for the initial assembly of the tanks that makes sense to me. I gather from Steve's site that he had followed the plans build sequence and didn't like the results. After reading the plans, the statement that the leading edge skin and the tank skin should be "perfect, elongate the skin holes if necessary" provided the needed nudge to try something a little different. I'm a builder that likes to see things and drill things in place whenever possible. I don't trust my measurements especially when as little as 1/32 off in a couple places would require elongating skin holes. The plans call for measuring and drilling holes in the center of the flanges on both sides of the 7 "Z" brackets. My take on this was dead center. I'm not that accurate. So here's my path, the idea stolen from Steve. I'll update if I run into problems.
First step is to drill an 1/8th hole in the center of one flange on each
"Z" bracket. I've found that with minimal effort, one can
sometimes create a jig that helps in these repetitive processes without having
to measure each individual piece. Or in my case, use the measurement as a
check point. I took a 2X4, drove a nail to use as the stop, centered the
first "Z" bracket in the drill press and clamped the jig in place to
be used to do all the remainder.
Next cleco the "Z" brackets to the baffle. I drew a line down
the center of the flanges, again as a check point. I then used a square
and the center line to align the "Z" brackets to the baffle.
Drill all 5 holes in the "Z" bracket and baffle.
Cleco all the ribs to the baffle and "Z" brackets.
Next I clecoed the leading edge skin (or top side) to the ribs and baffle.
It would not matter which side you clecoed on, I just knew that on my wings the
bottom skins were already off so this way would give me more visibility.
At this point you can place the assemble on the spar and align with the rear
leading edge skin before drilling the "Z" brackets to the spar.

It's late and will be continued tomorrow. Again, the point of doing this in this sequence is to allow you to drill one flange of the "Z" bracket with the assemble in place. I will drill the "Z" brackets from the bottom side of the spar.
I slipped away and drilled the "Z" flange from the bottom of the
spar. This really did work out well. It was no problem to drill
these with the bottom skins off. One additional thing going for me was
that my most inboard main ribs were backordered so they haven't been installed
on the main spar yet. This allowed me to get to the most inboard
"Z" bracket without having to battle between two wing spars.

Feb 15, 2002 2 hours
Attached the nut plates to the "Z" brackets and three nut plates on the spar. Started re-assembling the tank.
Fabricated all the tank stiffeners.
Drilled all the stiffeners to the right tank.
I placed the tank back on the spar and after one last verifying that everything
was aligned, I final drilled the holes in the tank _ leading edge brace.
Next was assembling the rib to the skin and final drilling the holes in the
skin through the ribs. 
I fabricated the T-405 bracket. While I was at it I went ahead and fabricated
the left one as well. It took a long time to fabricate the first one and only a
few minutes for the second one.
I'm not sure if these are small enough. It doesn't look like there is enough
room for the head of the rivets that go through the skin and ribs. We'll
see.
Worked on the interior ribs today. I did not have a fly wheel cutter
and needed to cut out the access hole in the interior rib. I went to a 3
hardware stores and finally found one that I thought would "sort of"
work. I did a little modification to the fly wheel cutter and then cut the
access holes in the ribs. It worked much better than I thought it would.
Next was to clean up the cover plates for the access hole. I drilled the
holes, deburred, dimpled & coutersunk where needed.
Riveted the plate nuts in place on both the left and right interior ribs.
(I'm actively working on the right wing but where fabrication is involved, I'm
doing the left as well.) Fabricated the anti-rotation brackets for the
fuel line.
Thinking about changing one tank to a flop tube.
Drilled the filler cap in place and the drain plug in the right wing. I
made the clip for both tanks to hold the vent line in place and drilled the hole
in the interior ribs for the vent line to pass through the interior web.
Probably go back to the wing spar to deburr & finish leading edge next. I'm waiting on the tank dimple dies, sealant and the left leading edge skin.