Category: Everything Else

EDIT 8/5/2020: the AK51H rivets identified below won’t work. See my later post regarding countersunk rivets. In my part 2 post regarding the fuselage side skin install, I noted that the TSi instructs you to use 4.0mm rivets to attach the skin in the dimpled locations, rather than 3.2mm...

I was only able to log about an hour on 14 July. I started to install the long side rail angle (CF-ANG-010-R-C) that runs the length of the side skin, as well as a number of gussets that connect this rail to the uprights. The gussets share a number...

I’ve been falling behind on regular posts, but I intend to return to a regular rhythm — if not daily, at least on the days when I work on the plane.. So, this post is a little longer as it captures work performed 8 – 13 July. I’ve started...

Sling Aircraft issued Service Bulletin 0017 earlier this month, indicating that the elevator torque tube may have been incorrectly assembled at the factory. The issue is that the elevator control stop plates may have been incorrectly attached with aluminum rivets, whereas stainless steel rivets are required for the shear...

I’ve started searching for a place to do final assembly. My two leading choices right now are at Nashua Airport and Fitchburg Airport. Both have larger “community” hangars. In my mind I pictured getting a private T-hangar, but I guess those are pretty rare, and even then, they are...

This weekend, I took a break from working on my heating system to complete the seat belt mods for the rear seat. Both seating positions now have a retractable 3-point belt. The second one went a little easier than the first, thanks to a few new tricks along the...

I’ve been busy designing a custom heating system for my plane, which is why I haven’t posted in a little while. My Sling 4 kit would normally include a cuff-style heater, which heats air by passing it over the exhaust pipe. It’s a basic system, but many small airplanes...

When I first wrote about my rear seat belt modifications, I initially planned to mount the inertia reel below the floor, and then cut a slot in the floor to route the belt up to the shoulder anchor point. However, the more I thought about it, the more I...

I’ve been continuing with my rear seat belt modifications. The shoulder anchors attach to hat sections, which are attached to the rear fuselage beltframe and skin. I fabricated the hat sections from 0.080″ aluminum. The sheet stock is too thick to cut with shears, so I used a nibbler...

I spent most of my Saturday pondering what to do about seat belts in the rear seat. My problem is that the Sling 4 kit was designed to use lap belts (only) for the rear seat. However, the likelihood of surviving a crash is greatly improved by having 3-point...