Step 1:   Cleco the skins back on and tape the overlapping skins tightly closed.  Remove a screw and using a #19 drill bit and a plastic mallet, with a wooden block backing you up, give a couple whacks as shown in the plans.  Rotate the drill and whack again.  Replace the screw and do the same for the other screw.  This puts a dimple into the skin which you will then proceed to drill out with a #40 bit. 

Put everything back together, taping the skins tight as before.  Then match drill through the hole into the unmarked skin with a #30.  Remove the screws holding the weights and drill through everything with a #19.  Do this one hole at a time and you're done. 

08/27/05  -  2 hours

Steps 2 & 3.  Deburr the resulting holes and put a light bend on the edges so they lie flat.  Dimple both skins for #8 screws and machine countersink the weight to accept the dimples. 

Using the hardware in the plans photo, secure the weight.  I did not need to do Step 4, which helps in case the skins pillow. 

08/27/05  -  1 hours

Step 5.    Rivet the final 12 matching holes in the skins, top rib, and counterbalance rib and you're done! 

08/27/05  -  30 minutes