Misalignment of CF-ANG-010 and CF-ANG-025 holes

Even with all the shims, remanufactured gussets and connecting strip CF-ANG-005 clecoed in place two of the holes in the CF-ANG-010 and CF-ANG-025 junction mismatch by more than 2mm. It is possible to get these to match if CF-ANG-025 is shifted outwards by this distance, but then the junction between these parts would not lie flat against the side skin. Shims would have to be inserted between the skin and these parts. Actually, when such a shift is done the fit between these parts and the other side rail components is much poorer. Also currently the top side connection of these components is perfect and the front side rail CF-CHL-031 sits vertically. All this would be thrown off if I attempted to line up these two holes.

I do not want to correct this misalignment by moving the CF-ANG-010 inwards as this would make the CF-ANG-009 even less parallel.

Now the frontmost mismatched hole has so little material around it scarcely plays any structural role. That leaves only the rear hole which might provide some strength to the coupling. I will consider manufacturing a 2.4mm doubler plate that lies horizontally inside CF-CHL-031/CF-CHL-009 bridging the two, including these mismatched holes and several fore and aft of them. It will be matched to the CF-CHL-025 holes preferentially. I'll get Sling's advice on this.

A counter argument as to why I should reposition CF-ANG-025 and thus CF-ANG-031 outwards by this 2mm mismatch is that currently a gap is visible between the top outer edge of CF-ANG-031 and the side skin. I'll get advice from Sling on this.

As to the last point, a middle-of-the-road step is to dump the shim between CF-ANG-009 and CF-ANG-031, accept a slightly poorer topside misalignment, and allow the CF-ANG-031 to shift outwards relative to CF-ANG-025, the latter not moving at all relative to CF-ANG-010. The connection between the CF-ANG-031 and CF-ANG-025 is poorer as well, but can be handled by upsizing to 4.8mm. This has the effect of closing the gap between CF-ANG-031 and the skin, at least near this connection.