Today was pretty much a waste. I made an attempt to countersink the AEX wedge. After seeing how others had been doing this, the only way to get the countersinks nice and even is to create a jig. Basically the hole get’s enlarged slightly and the countersink pilot does not have anything to hold onto to keep it straight. I had a nice setup going and got all the countersinks done on one side. test fit it and it seemed perfect. When I flipped it over and did the other side…I saw that I was countersinking way too deep. I went ahead and finished them all and test fit the piece and sure enough it slid around inside the trailing edge. A new wedge has been ordered.

The ultra-large holes. I should have put a rivet in one for comparison. I will say the holes are a bit larger than #30 when they should only be #40…

From what I’ve read, the holes do get slightly enlarged and that’s okay. It’s the only way to countersink deep enough to have the wedge sit flush against the skin. It should sit flush but not slide around. The skin dimples should hold it in place. Oh well…all a learning experience.