Should the drill guide be flush with the surface of the assembly when setting the drill stop?

The drill guide should indeed be flush with the surface of the assembly when setting the drill stop. This practice is crucial for ensuring accuracy during drilling operations. When the drill guide is flush with the assembly surface, it helps to align the drill bit correctly with the workpiece, minimizing the risk of misalignment that could lead to errors in hole placement or dimensions. A flush surface also enhances the stability of the drill guide, reducing vibrations and improving the overall quality of the drilled holes.

By establishing a flush condition, you ensure that the drill stop is set at the correct depth relative to the surface of the assembly, allowing for precise control over the drilling process. This is particularly important in aerospace applications, where tolerances are tight and deviations can compromise the integrity and functionality of the assembly.

In contrast, if the drill guide were above the surface, it could lead to drilling too deep or at an incorrect angle, which could negatively impact the assembly's quality and performance. Factors such as the size of the assembly or the type of drill might influence certain design choices, but for setting the drill stop, achieving a flush condition is key to maintaining accuracy and ensuring effective machining operations.