I had an email conversation with a new future Sling TSi builder over the past two days. While he is waiting for the kit to arrive, there is the hard question of “how to get started”. This question comes up for every new builder, and those that haven’t made up their mind yet, but need some guidance on what it would take to actually get started.
I remember from my own journey of when I got started, that the sheer amount of information out there can be overwhelming and finding some kind of guide-posts can be helpful to make a start.
I figured out where I want to run the wires a while back after some tinkering and I am using one of the strut channels for the length of the wing, except the very end at the wing-walk where I had to make one curve down the bottom.
The hardest part was figuring out a good way to come out the bottom where the wing-walk is, since the strut channel doesn’t go through there. On the last picture above, you can see when I finally managed to grip on to where I want the loom to come out of with the help of some duckbill pliers, which were a suggestion from my EAA chapters Technical Counsellor when he visited a few months ago.
Running the wire
With the question of where to run the wire solved, onto actually running the wires.
I am installing the Garmin GAP 26 Heated/Regulated Pitot Tube, which comes with a Regulator that needs to be installed next to the Pitot tube and controls whether the Pitot tube actually needs to be heated.
For this, there are three wires to run – two for the power and one for the discreet output, which integrated into the Garmin G3X Panel to show when the Pitot Tube is actually heated.
I ran the three wires through some braided sleeving to give them some extra protection and make running them through the wire channel easier in one go.
With that out of the way it “just” took a lot of back and forth, more use of the Endoscope and the thin arms of Juliana and repeated shouts of “push, push” and together we managed to run the wire all the way. She cheerfully pronounces “Congratulations, it’s a wire” as it came out the other end.
I was planning to finish to Ailerons, but unfortunately in my final prep, I realized that I received two right side balance tubes instead of a left and a right one. The missing tube should be here sometime next week, so until then, the Ailerons are on pause.
This gave me some time to finally make the big step of cutting out the hole in the Wing for the Pitot inspection panel. I received the heated & regulated Garmin Pitot tube from the Factory and verified that it will fit nicely on the back of the round inspection cover, so I will mount that and I can keep my square inspection panel I designed for some other time.
First I did a lot of measuring and marking based on the plans. Since this is truly a moment of measure-twice, cut-once I measured and re-measured a few times.
With all the marks in place, I started with cutting the pilot holes for the center mark and the cutting head.
I prepared most parts of the Aileron a good while ago, but I was missing a replacement for one set of ribs that were damaged, so I had put the Ailerons aside and finished the Flaps and Elevator in the meantime.
Now with the Elevator done and the replacement ribs in hand, back to finishing up the Aileron. After a quick inspection and deburring of the new rib I laid out all the parts and got out my small painting booth to prime the ribs.
Once the primer is set I can get onto assembling everything and riveting the Aileron.
We recently had a discussion on the Sling Builders Facebook group about the very visible growth of the Sling Airplane community. With the bigger size, the community is slowly growing beyond the size of a Facebook group. There are also some people do not use Facebook, so a separate forum allows more inclusion for everyone.
So armed with that, we have started a new community organized standalone website and discussion forum that will hopefully help both active builders, people interested in possibly becoming builders and active Sling Pilots to come together and discuss all things Sling.
There was only one extra part I had to do for 3 of the rivets that were on the bottom edge. In order for them to fit correctly, I had to shorten the rivets so they wouldn’t protrude out.
Aside from that, I just went to town and pulled the rest of the few hundred rivets.
The last part on the riveting side was the front lip.
One of the holes on the lip has to be enlarged to fit a grommet for the wiring for the Elevator Trim Tab. I enlarged the hole using my step drill bit and then installed a snap bushing.
The last part was to install the center balance counterweight. I did some test fitting with this, but the AN3-13A bolts that one of the versions of the manual that I have mentioned are too short, so I’ll check with the factory on the proper length.
With that being said, the general assembly of the Elevator is completed:
Timelapse of the complete construction of the Elevator
With the Elevator construction completed, I’ve also finished my video timelapse of the process:
When I finished the alignment of the left side of the Elevator, I ran out of clecos, so I bought a couple more when I was at Oshkosh so I could properly put the Elevator together and get everything to align correctly.
So the first order of business was to finish clecoing everything including the (correct) control tabs for the Trim Tab.
With that out of the way, I moved on to do the fitting for the right side fiberglass piece. It took a little bit of aligning and filing away a tiny bit from the back so that the fiberglass piece can slot into the metal.
Once that looked all good, I started to do the match drilling of the holed into the fiberglass.
Now the only last part to do was to countersink the front parts of the fiberglass tips in order to allow the flush rivets to sit in there. It took a bit of back and forth to calibrate my microstop countersink attachments to ensure I had a good flush fitting.
The two day workshop helped in explaining principles of airplane electrical systems, wiring and bringing everything together to design and build out your avionics.
Aside from a lot of good learnings and explanations, there was also a couple of hands-on exercises to get familiar with crimping, soldering and connecting things.
The first exercise was to hook up a headset jack to a PM1000 intercom system. This was very handy, since whether you decide to build all your avionics or not, you will most definitely have to do the headset connectors.
I forgot to take pictures of the process, but here’s the finished headset jacks with the soldered connection. This included learning to ground the shielded wire, soldering the actual headset jack and doing some d-sub crimping for the intercom connector.
Also shown in the image above is the result of the second exercise, a crimped BNC antenna connector. This part, I was already familiar with from hooking up my NAV Antenna in the Rudder a few months ago.
The final exercise was to create a small electrical circuit. This includes a “master” switch, circuit protection in the form of a fuse and a dimmable “cabin” light that is tied behind the master switch. Aside from the practical application of the exercise, it also tied together a lot of the theoretical parts of the workshop and was a great finish for the weekend.