Completed the installation of the fuel senders in the wings:

1. First, I had to make sure the sender floats would move freely inside the tank. Vans drawings and instructions are set up for those who built their tanks, which means they can clearly see what they're doing in there before they install the aft wall of the tank. For quickbuild people like me, we have to get creative with flashlights, borescopes, and such. The sender units are not 90-degrees to the sender plate, and I was suspicious of where that would place the floats, since there absolutely no guidance on that issue in any documentation. Just eyeballing it, the float in the right tank seemed like it would be mighty close to a nearby stiffener. I got an idea to temporarily install the sender, hook up the multimeter, and manually tip the wing so the float would move to its full ranges. And that's exactly what I did. The left tank float had full range of resistance (30-247 ohms), but the right one only went from 30 to 216, which meant the float wasn't moving all the way to the bottom of the tank. I removed the sender, snapped the float off and reinstalled it facing the other way (see Photo #1), and tried it again. Success. 30 to 247 ohms!

2. My biggest issue of the evening came when I discovered that there was not a screw-on nozzle included in the bag with my second Proseal cartridge. I ended up digging out the one I used last night from the trash. Since it was only about half-hardened, I was able to scrape out the old Proseal, clean it, and re-use it. (Photo #2)

3. I mixed the Proseal and applied a nice bead around the inside of each sending unit, where the sender is attached to the plate. Just for good measure, I covered the center contact rivet, too.

4. I decided to try a different technique with the sender plates than I used on the tank cover plates. I decided to run beads of Proseal around the tank opening, and push the sender plate into position on it, rather than make the beads on the sender plate. This turned out to be the way to go. I ran a thick bead around the edge, then around each screw hole, then a second bead parallel to the first. Then I carefully fed the senders through the narrow opening (trying not to get any Proseal on the senders in the process). I put in all five screws (including the one with the ring terminal and star washer), then tightened them down in a criss-cross pattern. This gave me a really nice bead of squished-out Proseal.

5. Used a mini paintbrush to apply Proseal around the heads of the attachment screws.

6. Connected the ground wires to the nearby spar bolts. (Again, this design feature is probably WAY overkill, but I really wanted a good ground, and it was easy to do.)

7. Used some of the remaining Proseal to go over every seam, rivet, and screw again. Wiped off what excess I could, and cleaned the socket screw heads with my finger. I hope I never have to take them off again!

Now, I'll work on some other stuff while I wait for the Proseal to dry in a few days. Once it's dry, I'll be pressure-testing the tanks -- the last major thing to do on the wings.