I found a leak in the seam of the outboard rib and leading edge. My poor balloon held air for a few moments before deflating to empty.
After drilling out the 250-300 rivets that held the baffle to the tank skins, I realized that drilling out the pop rivets that hold the z-brackets to the aft rib flanges would be a pain in the a$$. So after a little thought, I decided not to continue to remove the rear baffle.
So I gave in… I cut a rounded-rectangular hole in the baffle at the outboard end, to re-proseal the leading edge at the end rib seam, where the leak is.
I filed and scotchbrited the hole and a matching cover I made, the glopped a bunch of proseal along the inner seam. Unfortunately, there’s no way of knowing if I plugged the leak until the tank is sealed up again, so I’ll add a dollop of proseal to the rear corners of the outboard end of the baffle, just in case. Then we’ll seal it up and retest!