I just finished drilling my wings up finally after 3 years of work. Will be disassembling this next week to start the deburing and dimpling process. My wings were the vintage kit as well. I can say for sure the pre-punched skins and the dimensions called on the plans do not match. If I had to do this again I would by new skins with no holes and back drill my own holes. In the end everything has kinda of worked itself out.
Drilling and using the plumb bob alignment holes seemed to be a futile fight for me, all it did was give me a general idea of how things were changing depending on temperature that day, seemed to always change in the jig. Had I built them in my temperature controlled living room instead of a hangar in Georgia, maybe this would not have been a problem. Hanging the plumb bob over the spar and measuring is also a good idea. I opted to go to LOWES and get a long Sheet Rock square and used that instead. Just be sure to take a known square item with you to find find the truest square though, they are not all manufactured to exacting tolerances as I found out.
I did not drill my rear spar up on one wing and only clamped the ribs to the spar to drill the ribs up for alignment issues with the skins and ribs, this allowed me to move some of the ribs as required to get proper alignment. Once I had one side done I checked the alignment of the pre-drilled skins on the the other side before drilling the ribs to the rear spar and the skins to the spar. I did it this way to split the difference between the the alignment of ribs and upper and lower skins. Other than this I followed the the instructions as outlined.
I used a machinist square to insure my ribs were vertical to the front and rear spars.
Good luck and happy building.
Tom
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