I match drilled all the holes in the ailerons. First I drilled all the #40 holes.
The bottom skin to spar flange is #30 for pulled rivets. And the nose skin into the counter weight pipe are #30. I drilled them first with a #40 drill and then enlarged the hole with the #30 afterwards. I think this made the initial hole easier, and then minimized burrs on the inside when I enlarged the hole to #30.
I had this long 1/8th drill bit I bought from Boeing surplus so I used it to drill the nose rib tab to pipe. You have to slightly enlarge the bottom hole in the rib flange then drill through the tab and pipe. Went okay.
