Joined: Tue Jan 04, 2011 5:53 am Posts: 235 Location: Routt County Co.
Solely out of curiosity, do you cats follow the DIY instructions by drilling and installing one component at a time? I can't see any good reason for it, and I hate changing bits in the drill press. I just finished my 12th board and I've done them all the same way- 3/16 bit first for tip and c hooks - 1/8 for all pilots - 3/4 forstner - 19/64 - then the coutersinks. Install all hardware one ski @ a time.
If there is ever a timed build off competition, I want in.
I built a jig to do all the through holes at the same time for Sentury before they closed up shop. I did all the through holes first then everything after that was pretty much the same as you do it. I got pretty good at it and the board halves were always super tight with that jig every time. The trick is to clamp the halves together pretty tight and flat to begin with. Never timed it though.