Fitting inspection port to alumni. fuel tank

There won't be any top edge attachment. They had to fit the top last and therefore had no access to the top edge of the baffle. You're overthinking this. It's a simple job, don't complicate it for no reason.

I'm not; the body is folded and the ends welded on afterwards so easy to weld the baffle in place. Besides I've stuck a camera in and it is welded top and bottom. Not much point having a baffle that is only welded along the bottom edge
 
I've used those Wema FLB hatches successfully - just cut the hole and fit the hatch with one big bolt.

Flat rubber gaskets always seems to squeeze out I find, when you tighten the fasteners. Cork is more stable?
 
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