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Rob Wolf wrote:
> I've noticed that I can sort of squish the header tank inwards so that the
> flange fits more or less completely on the honeycomb portion.  

Rob,  My header tank, like yours was a pretty poor fit. Also the
"flange" was basically "rolled" off the header tank so that even if it
fit properly, it would make contact with the fwd deck only on one thin
line. I had very little confidence in the structural integrety of the
tank-deck assembly. If you're going to use the fwd hinged canopy this
assembly is especially critical. Here's what I did.

Cut the entire "flange" off of the tank.
Sand the top inch or so of the tank, inside and out.  
Marked a 2" wide line on the deck around the perimiter of the tank.
Covered the bottom (tank side) of the deck with plastic release tape.
Lay 2 bid, 2 inch wide tapes over the line.
Lay the tank on the deck.
Put 2 bid tapes around the perimiter of the tank 1/2 on the tank and 1/2
on the deck.
Let cure.
Pop the tank off the deck and you have a perfectly fitting, wide, cap
strip like flange.
Build a micro fillet on the inside and lay more 2 bid tapes around the
interrior side of the tank and let cure.
Hysol the tank on the deck with a strong, perfectly fitting, 2 inch wide
flange.

Its probably overkill but I know that it's never going to seperate and
may even be lighter than glopping flox in to fill the huge voids. I have
pictures of the entire process, let me know if you'd like them.

Bill Harrelson
N38BH
harrelson@erols.com
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