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:
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.
One of the things that the factory forgot as part of the change from the Sling 4 to the Sling TSi was the required access to the internals of the wing next to the Pitot tube.
In the Sling TSi design, some inspection panels were removed including the one next to the Pitot tube. By itself, if someone was building the wings from scratch, that might be fine as long as the builder installs the Pitot tube beforehand and doesn’t anticipate to ever need to access it, such as if using an unheated Pitot tube.
However, I am going to use the Garmin heated & regulated Pitot tube, which not only requires wires to be run to the Pitot tube, but also that I need to mount the regulator unit next to it.
Since I ordered the quickbuild, I ordered it with this specification, but unfortunately the factory didn’t receive the Pitot tube from their supplier in time and shipped my kit without installing it.
So after I received my shipment and inspected everything, I realized that installing this after the fact wasn’t going to be easy, particularly with the lack of a hole in the wing. Unfortunately the factory also forgot to run the wiring to the pitot tube, which creates a whole second issue, for which I’ve been working on a solution.
I informed the factory a while ago and also gave Matthew, one of the other TSi builders a heads-up since he hadn’t started on the wings yet. The factory realized their mistake in the plans and promised to come up with a solution and send me instructions and a plan.
Drafting a plan
While I was waiting for the factory to come up with a plan, I actually started drawing up my own plans to fabricate the entire inspection panel myself and used it as an opportunity to learn and use Solidworks, which I can use for free as part of being an EAA member.
Since I had the chance to chat with Mike Blyth at Oshkosh for a while and we chatted about my build, I mentioned that I was still waiting for the factory to come up with a plan for the inspection cover and he promised that he’d check on the progress when he got back to South Africa and indeed, two weeks later, I got an email with the plans.
The factory plans, in keeping with the other inspection access panels, uses the same flush round inspection cover that is used to access the Flaps and Aileron connecting rods.
Since I am still busy with other things in the build and haven’t actually made my own panel yet, I am going to go with the factory plans that they have drawn up for me.
Cutting a round inspection access panel hole
There is just one difficulty to overcome – the access panel is round and large and I don’t think there are 143.4 mm drill bits I can buy in Home depot.
Since this is quite an operation, I decided to get some practice with the tool on a piece of spare aluminum and also made a video of it, since I figured that it might be helpful for other builders in the future.
I started by marking out the circle using a drafting compass. It’s been quite a few years, but luckily I still remembered how to use it and how to find the center of the circle again by making two marks. Proof that you may indeed use what you’ve learned in geometry class sometime in life, even if it’s 15 years later. After that I clamped the piece of metal on the edge of the table.
I drilled the center pivot hole to 1/8th of an inch, which makes the pivot sit in the hole and then measured out the starting hole for the drill, make a starter hole and then used a step drill bit to upsize the hole until it aligned with my marked circle.
After that, I set up the drilling tool with the pivot and made sure that the outside of the cutting bit aligns with my circle and then attached the drill and went to work.
Here are a couple of pictures of the first circle I cut – note that briefly I had the pivot point jump out of the hole, which caused me to waver a bit which you can see towards the bottom where it’s not perfectly round, so make sure the pivot continues to stay in the hole.
Annotated video of the process of cutting the hole
It’s been a busy few weeks after returning from Oshkosh, so it’s been a while since I’ve written an update.
Since I spent the whole week at Oshkosh, I had a lot of time to figure out various bits and pieces that will go into the airplane and talk to the various vendors. I also finally got to meet Adam and Steve from Midwest Panel Builders who I’m working with for the Avionics.
It was great to get a feel for various things including the control sticks – I will go with the Tosten grip.
Another thing I was looking at is the TCW Control Valve servo for the vent shutoff valve that the TSi has. The standard design for this is a physical shutter that I’m not a great fan of, as I feel it looks a bit out of place in the panel. So I was looking for alternative options and Adam mentioned this servo as a possible option. After I checked it out, I think indeed it might be a nicer solution and I will try to make it work. In fact I might also use it for the heating control.
Aside from figuring out things for my own build, I also attended a lot of seminars, saw a lot of cool airplanes and the airshows and met a lot of interesting people and stories.
I also spent a lot of time lurking around the Sling tent and checking out various details of the completed Sling TSi that they had on display there. It was nice to see how a lot of the small details to the plans for the fit and finish were in this plane, which didn’t exist in Wayne’s TSi yet.
I was also able to meet a few of the other Sling builders at the Sling Ding meeting and had a long chat with Craig and Austin about our various builds. And I got to meet John & Marta King who I have to give credit to getting me through the ground school of my private and instrument training and ran into a few other people including Angle of Attack, Aviation 101, Jason Miller, JP The Candourist and Mike Patey and Draco the bush plane.
Time to finish off the Empennage and get the Elevator structure going. I received the replacement ribs that are bent just that little bit more in order to properly align with the reinforcement plates and skins and went to work to drill out the bad ribs and put in the replacements.
After that, I went to work and torqued the bolts that connect the control rod and counterweight to the Elevator. There’s also a small support bracket that reinforces the center rib to spar attachment, which is a pretty tight fit, so I had to get out the manual hand riveter.
My brother is currently visiting and is enjoying the riveting experience.
Once the center ribs were finished, we moved on to put the rest of the rib structure in place.
After that I realized there’s a mistake in the plans as they instruct to rivet the edges that hold some of the side counterweights on, but there’s another small end rib that actually has to go on there as I found out after I checked the overall plan for the Elevator. Quickly drilled out the rivets and riveted on the part. A nice trick I learned from another builder for drilling out the rivets without damaging the holes they go through, is to only drill out the top of the rivet (the donut ring) and then use the center punch to push out the back of the rivet. This way you have less chance of enlarging the hole.
With the rib structure in place, time to work on fitting the skin.
With the ribs for the Flaps out of the way, I am ready to finish the flaps. First order of business is to ensure that I have the ribs all in the right order.
Once that was figured out, I first clecoed the ribs in place to the bottom of the skins and then closed up the skins and clecoed the top as well.
After checking that everything is aligning properly with the skins, I started riveting the skin. The top side is pretty straightforward. For the bottom side, there are a couple of tight spots next to the hinges, so the close quarter rivet wedge came in handy for a couple of the rivets.
With the right side Flap finished and closed up, I then repeated it all for the left side Flap. There was also a couple of the edges where the hinges sit that needed a bit of deburring attention.
After I finished the top skins, I did one quick alignment test fit on the wings and everything looked good, so then I finished up both sides by riveting the front rivet lane that closes the skin against the other side.
Final alignment check
Once I finished all the riveting, I did one final test fit onto the wings. I used a bit of mason string and my laser level and everything is looking good. Now onto finishing the Elevator.
With the wiring finished and the Antenna fitting done, I am now finally able to close up the Vertical Stabilizer and rivet the skin.
To begin, I closed up the left side of the skin and held it in place with clecos, since this is the side where the Antenna slides through the enlarged rivet hole, while on the right side I had to create the custom notch so that I can pull the skin around the Antenna.
Once that was done, I riveted on the support plate for the Antenna onto the top rib of the Vertical Stabilizer.
Now that the structure is complete, time to mount the Antenna permanently in place. Using two 20mm long M4 screws, washers and Nyloc nuts and some medium strength threadlocker I mounted the Antenna in place. Here’s the Antenna mounted in place and the wire connected to the Antenna using the BNC connector I crimped onto the wire.
Riveting the skin
With all the prep work finished, I closed up the right side of the skin, made sure everything fits correctly and clecoed it in place. There are two holes on the bottom on each side that are not riveted, but instead I have to install Rivnuts in them, so I marked out those holes, so I don’t accidentally rivet them.
There were two rivets that I had to shorten in order for them to fit flush near the Antenna. So I made a small template for the dept through a piece of wood and then shortened them accordingly.
After that, it was just a matter of pulling the many rivets on both sides of the skin to close the Vertical Stabilizer up for good.
The last part was to install the two rivnuts on the bottom on each side, so after enlarging the holes using my step drill and reaming them out using my hand reamer, I got out my rivnut puller and high strength loctite and put those in place.
With the Vertical Stabilizer completed, I then did a quick test fit and mounted it on top of the Fuselage and also attached the Rudder for a moment – almost looks like an airplane.
This morning I had my first visit from my local EAA Chapter 84’s Technical Counselor to look over my build and give me some advice as part of EAA’s Technical Counselor program.
This was the first Sling kit for him and he was impressed by the quality of the kit, its completeness and the instruction plans. We looked over my completed parts of the Empennage and talked about wiring, avionics and things to look out for. He also gave me some good general advice and stressed the point of documenting, particularly around wiring, since many years down the line there’s nothing worse than finding a wire and not knowing what it is for exactly, so he was happy to see my label maker and my active use of it.
We filled out the visit report and agreed to meet again after I’m further into the build and working on the interior of the Fuselage.
Vertical Stabilizer wiring
Now, back to building. As I finished the match drilling of the dimpled holes the other day, I had to dimple the hole that was missing a dimple, so I got out my modified hand dimpling tool and quickly did that dimple.
After that I worked on finishing the wiring the run through the Vertical Stabilizer for both the Anti-collision light on the Rudder, as well as the NAV Antenna.
First I had to make another hole to run the Antenna wire through the top rib since the factory plans assume that you either install the light or the Antenna, but not both. I marked the hole location using the center punch, then drilled a pilot hole and then used my step-drill bit to up-drill the hole to the right location for the snap bushing to go in.
After that was done, I wrapped the wire for the light in some braided sleeving for some extra protection and then ran it through the rear holes. I also installed some flexible edge protection for the hole where the wire will meet the wire from the Rudder.
Quick test fit on the Fuselage
I then quickly measured out the length of the Antenna wire to install in the Vertical Stabilizer, cut it to size and ran it through the front holes. After I was done with that, I wanted to do a quick test fit of the Vertical Stabilizer Structure on the Fuselage to see where the holes would pass through.
Antenna Coax wiring
Once that was figured out, I moved on and did my first crimped coax connection. After a tip I saw on the homebuiltHELP channel, I bought this rotary coax stripper, which strips both the front, as well as the braided shielding in one go.
Before it was ready to use I had to do some adjustments for the lengths and depths for the cut, so I took it apart, while following the instructions and then moved the blade as needed. I’m using the SteinAir BNC Connectors, so I had to move the blade that exposes the outer shielding back by one position to the point marked E and the inner blade on mark B.
Then I adjusted the blade depth using the screws on the bottom and did a few test cuts to make sure the results are repeatable. I then put some light strength thread locker on the screws so they stay in position so I can now just use it without any further adjustments needed.
After that I did a quick test crimp of a connector to the small piece of wiring I used to calibrate the wire stripper, following the instructions from SteinAir.
Looked all good, so I repeated everything on the actual wire for the Vertical Stabilizer.
With all that done, I installed the wire in the Vertical Stabilizer and now I’m ready to install the Antenna and close up the skin.
Interesting side note on coax wiring and the use of a balun
One other interesting thing I learned while doing this – I tested the wire I crimped for continuity to make sure there are no problems with the wire itself by checking (lack of) continuity between the shielding and the center core. This was all good, so my crimp is good.
After attaching the wire to the Antenna however, I figured I’d also check it with the wire attached to the Antenna and had a brief moment of confusion when I did get a positive continuity readying between the core and the outside. So I did some digging and found out that the use of a balun (in my case with the Rami AV-525, it is an internal balun) can create a DC short and thus will produce a continuous reading using a Voltmeter.
Before I can close up the Vertical Stabilizer skin, I need to fit the Navigation Antenna, run the wires for the Antenna and the rudder light and fit the skin including up-drilling the countersunk holes in the skin with the rib structure.
So one thing after another, first I gave a quick test fit for the skin and then drilled up all the countersunk holes.
After that was done, I went to work to fit the Rami AV-525 Navigation Antenna I’m going to use. I already fit the Antenna onto the inner rib a while ago before I built the rest of the structure, so now it was a matter of fitting it all with the skin to be able to close the skin around the Antenna.
On the left side, the Antenna comes out one of the pre-drilled rivet holes, so I just had to up-drill that to the correct size.
For the right size, the Antenna comes out offset a bit further behind, so I marked out where I needed to make the hole in the skin, then used a center punch to get a good center to drill the hole:
With the hole in place, I cut back a small notch, so that the skin can slot around the Antenna since the arms of the Antenna are fixed to the internal balun.
After all that was done, I put it all together for a final test fit:
Looks all good, so now I need to finish running the wires on the inside and then I can rivet the skin closed.