Calling the fuel tank "finished" before it's leak tested might be jumping the gun a bit, buy I'm optimistic. Today was a long day, but once you start closing things up, there aren't a ton of great stopping points. All in all, it went pretty well. I modified a few processes from the first tank, did better at some things, and created new mistakes with some things.
One lesson from today is that when there is something that needs to be done, I need to mark it in a very obvious way, otherwise I just forget all about it. Case in point, in my final inspection of the internals of the tank, I decided there were two small areas at the front of two ribs that I wanted a little more proseal on. Because I hadn't mixed up the proseal yet, I didn't have any handy to just dab on at the moment. Fast forward a while and as I started riveting on the baffle, I remembered. Too late. I think it's probably okay because I was just going to add more out of an abundance of caution, but I won't know for sure until I leak test everything.
One thing that got me on the first tank as well as the second tank was the fit of the baffle. I don't know what the deal was, but on both tanks, the lower side skin was skewed by maybe 1/64", so the holes for the baffle/skin joint were slightly off. The baffle went together with clecos just fine, so I didn't notice the issue until I started putting rivets in (they wouldn't go in). I'm still not sure what happened, especially since the exact same thing happened on both tanks. I had to hit each hole with a reamer to just knock a little bit off of the hole. Even with that, the rivets wouldn't sit perfectly flat (because the skin in that area is countersunk, not dimpled - the dimples would have had a lot more forgiveness). They are just slightly at an angle - just enough to be able to catch a fingernail on one edge of the manufactured head. The top skin is perfect, so I'm not losing much sleep over it. It won't be noticeable for anyone who isn't out to find errors and crawling around under the wing! It was just a bit strange to have this happen on both tanks.
