Philip,
Welcome to the forum! I represent a vote for the Waiex. Here are my answers:
1) With the 'new' matched hole formed parts, do the holes still need to be drilled out to size for riveting?
Answer: All the pilot holes are 3/32". These need to be run up to #30 for riveting. Some of the thick stuff, i.e. 1/8" angle parts generally need the 3/32" brought up to #40 for the clecos to happily go through them.
2) For a given assembly of matched holes, is that to say ALL the holes (i.e. rib to skin) are already CNC punched?
Answer: Much of the matched hole stuff has the 3/32" holes in both parts, so you cleco together and drill out to #30. Some places you are required to transfer one set of CNC holes to another part. Examples I can think of:
a. side and bottom skins to longerons
b. turtledeck skins to formers
c. machined angle parts to side skins
d. wing skins to ribs (I am not there yet!)
I would estimate about 75% straight matched hole, 25% transfer holes from the CNC pilots to the other piece.
3) Do the factory matched holes required deburr and finish?
Answer: Yes. They need to be drilled up, then deburred.
I have seen an RV12 up close, but have no idea how it compares to the Sonex as far as building. I am sure they are good airplanes.
I have the machined angle kit, the parts quality is excellent. Generally I don't need to do any edge finishing on those parts. That says a lot, as I used to work in Ground Test at Sikorsky, where we were all about fatigue. On the fuselage I have probably had to make 2 or 3 parts according to plans, typically shims or flat stock with two holes in it. I have made some more parts that I screwed up, or was unhappy with. So far I estimate less than 10 parts.
Overall I give the CNC holes in the Waiex (and the kit in general) an A-. I have found a few spots where the holes were not perfect, as have others. I am very happy with the kit in general though.
You can check out my build here:
http://www.sonexbuilders.net/viewtopic.php?f=39&t=578I bought the Waiex to have an airplane to build with my 13 year old. He was 12 when we started. No regrets! It is a good kit.