Abstract: Drill jigs for positioning mounting holes using metrology processes, and associated systems and methods, disclosed. A representative drill jig system for positioning holes to be made in an object can include a drill jig having a plurality of movable plates. The plates can include: a rotatable plate carrying a hole pattern for positioning the holes to be made; a first translatable plate that is translatable along a first axis; a second translatable plate that is translatable along a second axis that is perpendicular to the first axis; and a base plate carrying one or more attachment elements positioned and configured to grasp the object. In some embodiments, the plates are manually movable via one or more adjusters. In some embodiments, the drill jig includes one or more servos for moving one or more of the plates under computer control, such as in a feedback loop using one or more encoders.

Abstract: Aerospace systems, and systems and methods for assembling an aerospace system or another system or structure, are disclosed. A representative system can include a propellant tank with a dome-shaped head; attachment features on the dome-shaped head; and a thrust structure with legs attached to the attachment features. A representative method can include forming shims to be positioned between the legs and the attachment features. The shims can be formed based on digital characterizations of mounting faces on the attachment features within a reference coordinate system. The method can include positioning a drill jig within the reference coordinate system and using the drill jig to make holes in the shims and/or the attachment features for fastening the legs to the attachment features. A drill jig can include plates that are movable relative to each other. At least one of the plates can include a mounting hole pattern.