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I dimpled the tunnel skin and counter sunk (120* X .250) the wing attach angles as the plans show, then reassembled for a test fit. I was very disappointed to see how badly the dimples nested into the counter sink. I could easily insert a .015 feeler gauge between the two. It looks much worse if viewed from the side looking into the tunnel.

Now I realize the clecos don't pull as much as a rivet, but it doesn't look like the rivets will pull that much space. I'm thinking I'll have to tap the dimple back a little so it fits better into the counter sink.

Has anyone experienced the same thing and how did you deal with it?

Does the rivet sits flush in the dimple? If it does, I would countersink a bit deeper. Using a scrap piece of 1/8" aluminium to get the depth. When it sits flush to your dimpled part use that setting on your microstop to deepen the counterunk holes on the part.
Steve
Sonex 892

I understand. Thanks Steve.

If the dimples don't nestle into the counter sinks of the female part deep enough to allow the two parts to lay flat against each other, I would counter sink just enough to allow them to.