what I've learned on my first tank
buy several 35cc monoject syringes. I mix about 3.5 to 5.5 grams of sealant at a time, load as much as I can, and freeze the syringe I'm not using. If I pull the other from the freezer when I'm prepping it is ready to go (thawed) when I'm ready for the sealant.
Fay seal, cleco, wait 8-12 hours. Any temps over about 65F will tack up the sealant enough to avoid a horrible mess.
Blue tape is valuable but I chose to apply a healthy bead of sealant to all areas that might be prone to leak.
It may be taboo to some, but I chose to smooth the fillet with a gloved finger and some MEK. That way I could see any voids much easier.
I riveted an extra tab to the web of the inner rib that I used to safety wire the vent line. I'd put it between the sending unit plate and the vent line, I however put it on the opposite side and it was a pain to reach and/or see.
Test fit the leading edge mounting bracket after riveting the skin and make adjustments, I didn't and had to clean proseal off of it, make adjustments, and then re-check, clean again, adjust, re-check, clean yet again, adjust, cleco and wait... total pain in the arse and could have been avoided.
In addition to a bead from the rivet holes foreward--the baffle got fay sealed as well. I used blue tape to cover all areas that the baffle would not cover when seated. I feel that the seal should be more than adequate.
I still plan to use the cork gaskets and tite-seal for the sending unit plate as well as the sending unit seal. RESULTS TO COME. I hope for leak free tanks the first time out. I've still got a bit of Proseal to go on the plate and anti rotation bracket before I can put some pressure to it.
Thanks for everybody's input.