With the wider front spars the the long 5/16" drill bit won't drill all the way through, after drilling the 1/4" hole. The quill on the headstock doesn't travel that far.
I've been using a short 5/16" bit to get a more centered start to the hole. I found if I drill it 3/4" to 1" deep, then start the long bit near the bottom of that hole, it goes all the way through in one pass. I use a lot of short in and out strokes to keep chips cleared.
My last step has been to use a "P" drill to open the hole a few thousandths. The holes wandered just enough, from each end, to still leave the hole slightly tight in the middle. I found that if I gently tapped the 5/16" chain saw file through the hole it cleared the slight bend and the 5/16" bit, being used as a gauge, fits perfect. It can't have taken off much.
All the holes are drilled. On to routing the spars.
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