So in taking the advice above, I rested the balloon method with the soapy water trick outside, I could not find one leak. I believe the balloons are just, well, cheap. To make myself feel better, and to also further take the advice above, I did not drill out any rivets, nor did I cut any access holes, I did slap on a dab of proseal on the baffle to skin edge as well as the shop head of each rivet. This leaves the only possibly place for a leak to be the rivet heads directly.

What really put me off was that the final fix was the locktite 290 in a very tiny pinsize hole combined with the vaccum method to suck it into the crevise, now that is covered with proseal, i feel better and warm/fuzzy.

Loctite!
 

I also had a minor leak - found it with soapy water.
It was also on the rear baffle.
Loctite sorted it as well.
125 odd hours later, no sign of any leaks.
Glad you didnt have to resort to major surgery to rectify.
Cheers
Richard
RV7
Sydney, AUS

If you can handle one more piece of advice (from someone who also had a leaking tank problem), try filling the tanks about two-thirds full with gasoline and see if it leaks.

Put the tank inot the cradle, and just wait a few days.

And if negative, then lie the tank flat and wait a few more days.

Now if the tank does not leak after all that, then you know for sure that the tank will not leak. Please note, that on some rare occasions, the air test will show negative, but there still may be a leak.

that's my next step, i'm itchin for an excuse to go get some 100LL and bring it home, after the tank test, it's going in my motorcycle :D:D


.....before I sell it to fund my fuselage order

Good thought!

However, you can save a few bucks by not using 100LL as the test fuel. Just use the fuel that you would normally use in your bike will be fine since all of it will be used for that purpose anyway.

Going on two weeks now with about 4 gallons of 100LL in the tank, sitting upright, no leaks!!