After the baggage door was clecoed together, I match reamed all of the holes in the assembly to either #30 or #41. Plans specify a 1/32” clearance between the skin and the roll portion of the hinge. I used a feeler guage to set the distance, then clamped the hinge using a couple of C clamps. Next I drilled thru the skin and the hinge. After match drilling these holes I checked the distance and found the clearance was more like 1/16”. So, I cut another piece of hinge. This time I clamped it to the skin using 8 side clamps—measured the distance to set the clearance at 1/32”. Drilled one of the center holes, and measured everything again. Worked from the center out to each end, measuring after each hole was drilled. This time the clearance came out to 1/32”—tossed the feeler gauge to the bottom of the tool box. Removed the clecoes from all parts of the baggage door and began deburring the holes.
