After deburring everything I set up the c-sink tool with some scrap metal. I created the c-sink checking gage (1/4" hole) for checking each hole, but once I got it micro c-sink tool set-up, it stayed fairly consistent. I found it easier to just check with a caliper. After a awhile I could see if it was the right size just by eye. I also didn't run the drill too long in each hole to keep it from enlarging the hole. I used scrap wood to hold the stub spar at just the right angle to keep the flange parallel to the table. I'm happy with the results.
Counter sink set-up for proper size/depth with scrap piece
Al lot of counter sinking, but results came out well
