Originally Posted by gotyoke
I think nearly every reply missed the point entirely. In the plans we are told the maximum dimensions of these particular holes, not a general rule like "countersink for a dimpled skin", which is where the 0.007" would apply. The OP is almost at the limit and sees a significant gap. In other words, the skin is not going to sit anything approaching flush with the spar like it normally would in most cases, and that is the main concern.
You are correct that the .007 rule of thumb doesn't apply to countersinks for screw dimples but the principle for why
there is a specific limit and not a statement of "cut until the dimpled skin lays flush" is the same.
Bottom line is, that the dimension limit is given for a reason, whether it be .007 deeper or a specific maximum cut diameter, and it sounds like the OP has resolved to use that as a guide.
As a side note, the quality / crispness of the dimple is a large factor in how flush a skin appears to lay when a dimple and countersink (or even two dimples) are involved. This becomes even more pronounced in cases of larger dimples for screws. I believe many builders have been fooled by this in the past, and pressed on making their countersinks deeper and deeper in an attempt to get a flush fit, only to destroy their spar in the process.