I was never really comfortable with the previously built drill guide. That is, the one made from 0.050" plate bent into a "U" shape and some tubing. I was afraid there was too much flex in the plate and this would result in the drill not penetrating the spar perpendicularly. Instead, I got a rigid frame welded up with the guide tubing as one piece. I will cut the centre section of the tubing to permit clearance for the spar and the plates that were cut by the waterjet.

I marked the outside edge of the spar connector plate to show where the holes are and then transferred those marks to the spar once the connector plate was fully inserted into the spar. This will allow me to ensure that the guide plates are located properly.

I drilled the root end of the spar for holes for the bushings that the end plate screws into.