Happy Monday everyone,
I just talked to Vans. We quickly went through the plans on 10-11 step 2 and 3 and then page 10-12 step 9. His feedback was if I already drilled the side skins to Longerons under the aft deck with a 3/32, go ahead and match drill to #40. Any fairing screws, which some of these will be used for, will be enlarged for the fairings anyway.
We did look at the instructions and he indicated the #40 drilling was probably best called out in 10-11 step 3 even though that step does not call out drilling of the longerons.
I then asked when the plans call for using a 3/32 drill, can we substitute a #40 drill. The response was if the plans call for a 3/32 drill, use a 3/32 drill.
Based on the above responses, my suggestion to others is on section 10-11 step 2, drill using a 3/32 drill. On step 3, drill only the holes associated with the sides skins, and frames (not longerons) using a #40. this is exactly as called for in the plans. Where I would augment the plans is on section 10-13 between step 3 and 4 to match drill the side skins to the longerons under the Aft deck, after any additional adjustments are needed based on the instructions. That is the step on I am on now and it will work out just fine. I guess you could also final drill to #40 after Section 10-12 step 9 as well.
I will final drill the holes today to #40 and then start my disassembly of the cone.