05/10/2021 - countersinking windscreen holes - 3h

With the drilling completed, it's time to countersink the holes in the windscreen for the countersunk attach screws. Make sure you do the countersinking before enlaring to 5/32 so that the pilot of the countersinkcage has grip and avoid wandering holes.
As you can see in the image below, my pilot holes are still #40 here while i'm already countersinking. this required making some test drilling to get good countersink cage dept prior to starting the work.
As the screw can't still be inserted in the hole, there's no way to verify depth with the real screw until you open up the hole to 5/32".

Couple of holes done.

 

Next enlarged the holes in the plexy to 5/32". First updrilling with an acrylic drill to #30 and then using the 5/32" reamer to finish it of to a silky smooth hole.
As you can see, great alignment as well.

Articles in Finish Kit

Finishing Kit

Legal Mumbo-Jumbo

It’s possible (not likely) that I’m not as smart as I think I am. (Occasionally, I have moments when I know this to be true. Fortunately, the feeling passes quickly.) Although I have tried to make this information as accurate as I can, it is not only possible, but also quite likely, that erroneous and misguided information lurks within these pages. I cannot and do not warrant these pages to be error free and correct. Furthermore, I accept no liability for the use of this (mis)information. And, as many would say, your mileage may vary. If, after reading this, you are intent on proceeding, please be aware that the contents of this site are protected by copyright (copyright © 2011 and 2012). Nonetheless, you may copy this material subject to these two conditions: (1) any information used is for non-commercial purposes, and (2) the source of the material is properly credited. Of course, you may link to any page herein. At some articles, snippets of the plans from Vans are visible. These are for educational and illustrations purposes only and should never be used as plans for part construction or assembly as plans may have changed since the picture was taken and more important they are protected by Copyright by the Vans Aircraft Mothership company.