SonexBuilders.net

That bit looks 100% better than the McMaster Carr. You have much more surface contact! Plus more usable length(you loose an inch on the McMaster),and a non cutting pilot you don't have to dull and risk making smaller! No question which one I'm using! Thanks for finding it!
Now I might sleep half the night till I get this done.

Here are McMaster Carr pics for comparison.

I wonder if the 3/16" bit works as well. Neat idea.

Hello to all. I'm at the stage where I have to decide which method of drilling the wing blocks. Should I use the Sonex method with a piloted drill bit or Steve's alternative method of drilling the wing blocks to 3/8" early in assembly? Any and all thoughts are welcome. A big thanks to Steve for taking the time and effort to illustrate his method so clearly.

Gunther

I went with the Sonex method and screwed it up, added about a month of extra work to fix things up.
If I were to do it again, I would go with the alternative method.

Having gone through this twice, and now about to do it the third time, all I can say is pick your poison.

After long, detailed conversations at the ASA fly-in this weekend with people who have far more experience than I do, I made my own choice.

I will report the results once I finish the rigging - hopefully next weekend….

For all those who suffered through my endless questions this weekend, I thank you - hearing that others have experienced this frustration and how they worked through it really boosted my confidence to get it right this time. A very special thank you to Robert Frost for his patience and conversation.

I messed mine up using Sonex method but the second time I made sure that the pilot was completely dull. First time the pilot went off track.

Be sure to make the pilot is "completely dull."

Pete

Where and what drill did you get that was different than the Mc Master drill you are showing in post? I will be rigging my wings soon and am not sure which way I am going to do it. This will be the second attempt to rig the wings.
Don
Waiex 132

I successfully rigged my wings on the first attempt last week. I was able to borrow Chris Madsen's drill bits that he posted on the first page of this thread, here's a link to the non-cutting piloted 3/8" drill bit.

http://www.fastenal.com//web/products/details/0350457

That drill bit was perfect. It followed the 1/4" hole without the pilot cutting, and the best part is the double-margins did no cutting whatsoever, so my entry holes did not get enlarged. I think that at the very least a double-margin bit is essential, since the bit will spend so much time in the hole you don't want it making the entry hole bigger as you go.

I also used a 6" long 1/4" drill bit to make the first holes, and a 6" long 3/8" bit to finish the hole (the double-margin bit was about 1/8" too short to finish the far side of the hole.)

Ryan - thanks for the update!

I have been trying to think my way through the whole thing (far too much I may add) and that was one concern I had.

Ryan
Thanks for the information on the drill bit. I can see how this may do a better job than the McMaster drill.
Don
waiex 132