Decided to try the captive studs on the body hinges today. I marked the holes on the outside of the Inner Skins first just to make sure they would be under the Outer Skins once they were glued together. Everything looked ok, so I drilled and bolted the hinge for one panel then placed the Outer skins back on and clamped them down. You can see below that there is a pretty good gap. So I'm nixing using the studs on the hinges altogether and will just glue them to the inside instead. Some may be able to live with that gap, but not me. I think its just because the studs are so close to the edge, in fact, they may have even stuck out a tiny amount once glued together. So lesson learned, at least I only tried it on one hinge.
Also yesterday I went to the parents house and used the drill press again. This time on the other foot drive to foot shell holes. I still had a similar problem as with the first one and had to use a larger hole and even ended up filing a little on a couple holes to get everything to line up right. I started wondering was why Jerry doesn't go ahead and have the holes drilled in the feet when they are made. Seems like a machine would be able to be exact and alleviate a problem on the builder end. The only thing I could think of was that other drive systems may not use the same holes, and you'd end up with unnecessary holes in your feet. Something I may ask one day if I ever meet him in person. I also decided not to countersink the holes. The steel is just too thin. Looks like maybe 1/8th inch think at most. I'll still use the low profile flat head screws though. I think they look a lot better than the rounded fatties and will hopefully blend in a little more when everything is painted.
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