When repairing a minor metal-bonded honeycomb assembly skin delamination, how can you prevent core damage while drilling holes?

Using a drill stop is the correct approach when repairing a minor metal-bonded honeycomb assembly skin delamination to prevent core damage while drilling holes. A drill stop is a tool that limits the depth of the drill bit, ensuring that you do not penetrate too deeply into the honeycomb core. This is crucial because excessive drilling can compromise the structural integrity of the core material, leading to potential failure of the overall assembly.

In the context of honeycomb structures, the core is often made of materials that are sensitive to oversizing or damage from drilling. By setting a specific depth stop, you can avoid hitting the core altogether or limit any incidental contact, thereby preserving the core's properties and preventing degradation.

Additionally, while pilot holes and smaller bits can help guide and fine-tune the drilling process, they don’t inherently provide a mechanism to control the depth of the drill bit in the same direct way a drill stop does. The use of a backer block can assist in stabilizing the material during drilling but may not effectively prevent core damage if the depth isn’t controlled. Thus, a drill stop is the most effective and direct method to mitigate the risk of damaging the honeycomb core during the repair process.