Drilling Bolt Holes in Wings

There are two questions that I now need to bring to Van’s on Monday when I get a chance. First off, as you’ll see from the image below, I drilled the wrong hole for the bolt that will hold the fairings on to the airplane between the wings themselves and the fuselage. I thought these were just standard nut plates (which 7 of the 8 are) and I simply drilled all the ones I saw in that pattern…. Unfortunately this one near the J stiffener is a different type of nutplate (one that has two rivets then the nut rather than a rivet-nut-rivet combo) This is a pretty expensive mistake as I will need to replace the inboard rib, the reinforcement skin below it, and then the inboard top wing skin. This will set me back about $200 each wing roughly and that’s without shipping. I’m going to talk with Van’s first to see if there’s anything I can do. Since the nut plate will still have one rivet to hold it in place, and it isn’t structural, there might be a way to save this mistake. I have learned from this mistake that I need to basically check off every single hole and not make assumptions from the majority that they are all the same. They had clear identifiers for how many holes were between each bolt hole so I could have counted that way. Luckily I checked afterwards otherwise I would have happily built on and riveted the skin on and everything.

The second question goes back to when I got my laser-cut part replacements. I noticed that the replacement inboard rib had many more flanges than the original did. But I saw that it was still labeled as a W-1010L/R so I went ahead with it. Unfortunately while i was drilling the holes for the nutplate attachments I saw that two instances had way too little material between it and the edge. I’m going to have to verify with Van’s if this was the correct replacement part and if it is then is it acceptable to have this little amount of material between the rivet and the edge of the part. From what I’ve read it isn’t acceptable in any circumstance and could lead to cracking. Maybe this part was mislabeled and sent to me? It is the proper thickness material though (0.032″) and it works except for that one issue. I should have kept the laser cut ones I originally got just to compare it even more against now that I’m seeing this but… I try to keep my work space as clean as possible and if I leave extra parts that I don’t need around anymore it would quickly get overrun. We’ll see what they say on Monday and whatever is best is the way I will go. If it is the expense route, so be it. I just want to build this plane properly.