I decided to put the whole thing back together except only cleco the skin to the top flange of the ribs. I figured the ribs would still be able to support the baffle and keep it nice and flat, but with the bottom surface un-clecoed, I could eliminate the possiblilty of the ribs not being fully pushed into the nose bend of the skin as Bruce at Van's had suggested.

While I was clecoing the assembly back together, I noticed some light getting through the junction of the aft rib flange and the baffle. So I disassembled and deburred the baffle, ribs, and Z brackets. I even removed the blue plastic on the aft face of the baffle. It's only a few thousandths of an inch thick, but I need all the help I can get.

After reassembly, there was very little light getting through the junction of the aft rib flange and the baffle.

Once the whole shebang was clecoed back together (except for the bottom surface of the tank skin), I set it on the spar.

Argghhhh! There's still .040 inch gap! I'm gonna have to put out a call for help on this problem. Maybe I can get someone to stop in to look at this beast.

After updating the website and posting a message, I decided to do some deburring.

More plastic peeling. Good thing I didn't do all the skins at once. My fingers would be numb.

Ahh, fresh aluminum. Ain't it purdy! :-)