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Originally Posted by sf3543
You could also just buy some sheet aluminum and after you drill off the existing skins, use them as a template. Set the old skin on the new metal and drill through all the old holes, clecoing as you go to a piece of plywood, and you will have a perfact match. I have done this and it works great.
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Since the skin has already been dimpled, the holes are probably bigger than #40, and centering the new hole will be difficult. One good option is to drill them all out to #30 (after the skin is removed and is sitting on the bench....

...) and then use a transfer punch to mark the hole centers. Since you are going to be putting the dimples on the new skin into the existing dimples on the ribs, you need as much accuracy as you can get to ensure the new skins will be smooth. The dimples will define the alignment.
Transfer punch
gil in Tucson ..... did this on a major fus. skin I over-trimmed...
