Pic 1. Shows the notes I made in trying to decipher the meaning of the 8 step construction process listed on pg 10-3. The first issue is one of definition: Step 1 on Pg 10.3 states: Temporarily install bolts completely thru the "SPAR CARRY-THRU.' However, the "CT PIck List" provided identifies ONLY the part CT-011 as the "Carry Thru Assembly, Front Spar." But apparently the "Spar Cary-Thru" on pg -10-3 really means the entire assembly shown on that page and this consists of 12 separate pieces: CT- 011-01; CT 011-02; CT-011-03; CT 027 and CT -045.
The next issue is the description of the step drilling process....
After spending some time on this I sent an email to Mike who summed it up very well. With kudos to Mike I will summarize his comments here:
Every hole is drilled to a #8- EXCEPT those in CT-011-01. The step drilling identified in Step 2 and 5 which is done to both sides of the "Spar Carry-Thru" begins with a .125 and ends with an #8. The first drilling with a 0.125 is probably unnecessary and you can begin with a #30 or #29 and step drill sequentially with a #19, then #12, then #8.
I initially step drilled with a 19 x 30, then to #12 then to #8. I did not find any difference in the "perfection" of my drilled holes if I went from a 19 x 30 directly to an #8. I found that step drilling the same hole multiple times with a successively larger bit led to more chances of an errant drill. A nice drill press would save a lot of time here and increased accuracy.
Pic 2. Step drilled to # 8 EXCEPT in CT-011-01 which remain at #20 with Black Cleco's
Pic. 3. We marked CT 011-01 with Blue tape so that we would not mistakenly drill those large that the #29 called for in the plans. The two rows of holes on the front side of the "Spar Carry-Thru" were step drilled to a #8. Thanks to Lance for this suggestion.
