OK, I guess I couldn't really expect for things to go 100% smooth for the whole build right? I was just drilling and clecoeing along when this happened. I was used to drilling through all the matal of the spar, spar doubler, rear channel and two sets of skins (fwd and rear) then got to a thin area. Well... I used the same pressure and ended up tearing the thin rib below the skin. I though I had just missed it, so I went 10mm over and re-drilled. This second drilling went in between the rear channel and the rib. Luckily this area doesn't take much of a load being in between the spar and the rear channel. It is pretty thin aluminum to begin with. I cut off the edges where the metal was torn, then smoothed them out so it wouldn't crack and spread under vibration. The holes that went between the two parts just rode in between them and didn't pierce anything but the very edge of the rear channel. I adjusted the rivet spacing and put one on each side of the affected area, keeping proper edge and rivet spacing in mind. The holes with the "X" over them are where I left the rivets out. I'll cover these over and smooth out with bondo when I smooth in the tip caps to the aluminum. Just like I did for the tail light fairing on the rudder.
