Sling 4 for Matt Build Log

Continued work on horizontal stabilizer parts including deburring rivet holes, edges, and rounding corners. The work is slow going, but I'm happy to get the parts to the point I know the mating surfaces will be gap free. The grommets for the trim servo wire are barely big enough to fit the provided 6-core wire and too big to fit in the pre-drilled holes in the ribs. I increased the rib hole sizes to 3/8" since the caliper measurement outer diameter of the grommet measured 25/64". The grommets fit and the wire is able to pass through the new diameter. I need to go back over the nose ribs and round out the corners I skipped. After that, I'll be ready to clean and prime the horizontal stabilizer parts, but I won't be able to assemble the complete frame. One of the plates is being replaced and not due to arrive until April. I want to take a moment to describe my parts inspection/preparation process. I don't know if it's more or less than other...

The fifty 5/32" clecos that I ordered arrived and I was able to test assemble the entire horizontal stabilizer. I also got a sense how tight riveting will be from the rib side since the nose and middle ribs butt against each other in the forward spar. Having little fun with AC/DC playing in the background On to serious work: Half-way there All the way there In the first picture above, you can see the dark spar doubler plate connecting the left and right spar channels. That was the primer test piece. After 24 hours, it passed the tape test. I started with blue masking tape and realized this stuff is made to come off easily. So I applied some very sticky clear packing tape, making sure to press it down on the primer. It came off without a single speck of primer or residue. I then conducted a scratch test. The primer scratched off easier than I expected, that is, with not too much force. So, I will conduct the scratch test again after 72 hours of lay-up. A no...

Spending a lot more time deburring edges and rounding corners than expected. The holes are relatively easy to debur compared to other projects I've helped out on. But most of the edges are either rough or have significant projections that need to be taken out. The photo above was taken through the bench mount magnifying glass. The lower edge was cleaned up using a file and Scotch-Brite 7447. The upper edge is untouched and indicative of many rough edges in the kit. It's expected this and I rather enjoy the process, but just time consuming. I think the 7447 is the perfect grit for finishing after files or sandpaper and scuffing for primer. One of the plates had a deep scratch that I worked out with sandpaper and then the Scotch-Brite pad. Looked flawless afterwards. I am waiting on the primer test piece to dry to determine if my priming process is sustainable. According to my two Navy airframe mechanic neighbors, "tape testing" the primer is a suitable test. I...

I'm still waiting on tools to arrive, but I do have enough to prep and prime parts. I am going to try the following process on one part this weekend to ensure good prep work: Assemble parts with clecos and inspect for good fit, defects, or damage Remove protective film and debur. Inspect for scratches Clean parts with Simple Green Extreme Aircraft using 3M Scotch-Brite Pad 7447. Wipe down with distilled water Using nitrile gloves, wipe down with acetone Spray two coats of Rust-Oleum Self-Etching Primer and let dry for 24 hours I will assess the process by the end of the weekend and either need to adjust or be ready to move forward.

While waiting on clecos, deburring tools, cleaners, and primer, I decided to get started on removing the protective film from the horizontal stabilizer internals. The blue film comes off pretty easily, but the clear film puts up a fight. The clear film also leaves a lot of adhesive residue, which is likely due to the parts having been covered for a long time. It's also notable that along some edges where the film had been peeled back a little, the aluminum is noticeably oxidized. All parts accounted for. Removing the film from this spar doubler plate revealed a series of uniform scratches in the surface. It looks like they were created during the CNC process and cover a good portion of the part. I'm going to ask TAF about it.   Manufacturing marks in this plate. Shipment tracking indicates some of the tools I ordered will be arriving today and some on Friday. I suppose I'll start making more progress as the week continues, but I hope to get a good pace going...

It was a very productive weekend, other than royally ticking my wife off. On Friday, I hit the hardware store after work for materials to build my first two workbenches. Before starting Saturday on the workbench, however, I needed to take Christmas lights off the eves. There was a neighborhood powered lift for this purpose, but the organizer sent it back Friday thinking everyone had finished. I had to do it the old-fashioned way by climbing up to the roof and reaching over to the eves to pull the lights. To make a long story short, I fell off the roof at some point. Back to the workbenches... Here are a series of workbench photos: TAF crate setup as temporary workbench to build permanent workbenches. Building Chapter 1000 workbench upside-down per instructions. First workbench completed. Using first workbench to build second workbench. Two workbenches completed. Benches in place with build manuals and clecos on shelves below. Now it's time ...

My garage now only has the empennage kit. All other components (except the BRS) are in storage. Apparently, the storage company frowns upon the storage of ballistic materials. Being a Software Engineer, I have my proclivities when it comes to project management. To that end, I am using one of my favorite tools for organizing work: Trello . If you're familiar with Agile/SCRUM, you are probably familiar with it too. Here's a list of things to do over the weekend: A little bit more garage organization and lighting Build workbenches (EAA Chapter 1000 type) Buy air compressor and pneumatic rivet gun Buy handheld rivet gun, riv-nut puller, reaming bits, drill bits, fine-point markers, and deburring tools Buy 3M Scotch-Brite pads, cleaner, de-greaser, nitrile gloves, tack rags, lint-free rags/towels, and self-etching primer Build primer paint booth I also need to consider the following: Order Rudder replacement skin Order VOR antenna Order elevator trim servo (sti...

With the help of my dad and nephew, we moved the wing kit, canopy, main gear, and fuselage into my storage unit. I dropped off the moving truck much to the delight of the manager. It turns out California is running out of moving trucks due to one-way rentals to more friendlier states, like Texas. I'm not surprised. The empennage kit, fairings, BRS,  and remainder of the fuse bits are still in my garage. The emp kit will remain, as that will be the first component I work on after I get appropriately tooled. For most (myself included), the timing to start a build permits some lead time between ordering the first kit and tooling up. I didn't have that opportunity. But, don't cry for me, I got a good deal. I don't have an air compressor and that is something I would consider an essential tool. If I was going to attempt the final paint job on the airplane, it would be absolutely essential. But, I don't know. A cordless electric rivet puller is appealing for many r...

After a full day of inventory and sorting items into their respective kit components, I'm nearly done. The empennage, wing, and canopy kits are completely sorted and packed. The fuselage, undercarriage, and finishing kits are near done, though there are a lot of "mystery" parts for the fuse since they've been primed already and have no identification. I've already identified plenty of mystery parts from the construction manuals, so it's just a matter of time and patience. I do have to say that I'm impressed with the quality and completeness of this kit. I've researched many manufacturers and TAF appears to provide the most complete airframe kit out-of-the-box. Of course, you do pay a little more for this convenience, but it's worth it. Today, I'll move everything but the empennage kit into storage, return the moving truck, and take Christmas lights down.

Day two after arriving home and still sorting an conducting inventory on kits. I found a dent in the trailing edge of an elevator skin that I believe existed in the original factory shipment and was not detected the first time around. Other than that, it's a taxing process. I have a storage unit that I'll leave kit components at while I'm not working on them. I am also on the waiting list for a half dozen hangars at Gillespie Field. If I get a hangar, I will most likely store and build there rather than in my garage, even thought this is not a recommended approach to homebuilts. Hardware packages All of the hardware packages have been separated out and I plan to put component kit specific hardware in their own labeled storage box. The fairings will got into storage after a thorough inspection. They get to enjoy the luxury of being kept well protected and well out of the way. Hopefully I make bigger progress over the next couple of days so I can get to taki...

I made it back from Indiana Tuesday evening. The task of moving the partially completed Sling 4 kit took me across eight states, several rain storms, heavy crosswinds, a blizzard during the entire New Mexico leg, and mountainous snow driving over half of Arizona. The packing job wonderfully executed by the seller, his brother, a former co-builder, and me proved worth the 4 hours it took to complete. Nothing in the truck moved despite the endlessly horrific road conditions, bouncing around, and downright airborne-launching potholes and other imperfections in these great interstates. What a fantastic way to spend New Year's Eve and the first day of the new year. When I return to work on Monday and people ask, "How was you New Year's?", I'm sure I'll smile, even chuckle a bit, and reply, "Oh, you know! I did the usual stuff." Today I unloaded most of the truck and have been inventorying the kit items. Unfortunately, due to the previous inve...