Sling 4 for Matt Build Log

I haven't posted in a couple of weeks because I haven't built anything in a couple of weeks. It's a combination of being significantly bogged down at work and waiting on some parts from TAF. I go the word today that my parts are being shipped. I look forward to making some progress this weekend.

I started to fit the rudder channels and ribs together and ran into trouble right off the bat. The gusset channel (RD-CHL-002-X-A) that reinforces the bottom rib (RD-RIB-001-X-A) and control bracket (RD-CBK_001-X-A) does not fit in the rib as specified. I recalled that a TSi builder reported this last week on Facebook and some other Sling 4 builders confirmed the same situation. Only one builder has reported that TAF responded to a fix that involves using fluting pliers to pull in or shrink portions of the gusset channel so it fits. The original poster of the problem, Mike Black of Jet Black Machine came up with a good modification to the gusset that I am going to try (try not, do or do not). I agree with his assessment that it is structurally sound, even though the factory hasn't responded yet. I will post pictures later detailing what I've done.

The workshop (aka "garage") has been cleaned and organized again. This is becoming a regular weekly activity, and I think it's good practice. At least for me. I've been combing through my project planning after identifying every last mystery part in the center fuse. I even figured out how the front inertial-reel seat belts are installed, which the manual doesn't cover well enough to understand. I managed to figure out by browsing through all of Craig's factory photos and finding a couple with some obscure references. Maybe I've missed a few memos, but there are few tasks with the build that aren't very obvious.

I riveted the main spar to the CF. About one-fourth of the skin's holes required minor reaming to receive the rivets. Afterwards, I drilled out the twelve aileron stop rivets. Only one of them was problematic, with the mandrel broken at the surface. It was impossible to get a clean drill out of it. I flipped the stops around and re-joined them. NEXT STEPS Figure out what rear fuse work needs to be done and verify parts and build Verify work in E1. Do the parts bolted to the web need to be riveted? Check torque. Verify E3 work. Rivet main spar in E3 (verify using 4.0x10mm alu-multi rivets). Fix aileron stops in E3 Installing missing center console rivnuts and enlarge screw holes (need to place order for #8-32 rivnuts) Verify E4-E9 Install soundproofing Assemble/Install Finishing manual 1-4abc Assemble/Install Finishing manual 10, 11, 18 At some point receive replacement parts for rear seat location modification (E16, E17, E18) At some point receive some emp replaceme...

I am going to take a page from Craig's early days blog posts and start adding enumerated task lists to the end of each post. I use Trello to track tasks that depend on other resources (i.e. damaged or missing parts, orders, questions to the factory) and I keep a WBS/CP diagram to help me know what order work should occur in and remind me of what done looks like. But I still find myself staring hopelessly at all this data and unsure of what task to engage in. I've jumped from the empennage to the fuselage while I await the arrival of replacement parts from SA. I've gotten to the point where I have identified all the mysterious pieces for the partially completed rear and center fuses and have a good plan for going forward now. I hope that I've identified all the work that has to be re-done as well. For now, here's my plan: NEXT STEPS Figure out what rear fuse work needs to be done and verify parts and build Verify work in E1. Do the parts bolted to the web ne...

I planned to install control tubes and connecting rods today while I had the flap torque tube out. I started to install the rear bushings on the pilot-side control tube before I discovered another mistake the previous builder made. Here is the rear bushing bracket: I locked the upper nyloc down. I reviewed the Finish manual for details on how the autopilot control rod attaches. That's when I noticed the diagram in the manual and the parts installed in the fuselage deviated. Here's the aileron autopilot page: Note the orientation of the aileron control stop bracket (highlighted). Now, note the orientation of my aileron control stops: They are backwards! I went through the fuselage manual to see if their installation is specified there. Sure enough, they are and they depicted in several manual pages (if you look close enough using the PDF versions). The page they're installed on is E3: The aileron control stops were installed pursuant to the Fuselag...

Don't skip page E2 of the installation manual. If you complete the work all the way to page E8 and realize E2 wasn't done, going back is has its challenges. The previous builder overlooked page E2: Installation of aileron autopilot and yoke control brackets. These steps are much easier when the main spar is out of the fuselage. Additionally, the autopilot brackets share six rivets with the front seat ribs, so don't rivet your brackets in until the main spar is mated with those. Getting the autopilot brackets installed was impossible with the flap tube in. I had to drill out about 36 rivets to remove the flap tube bush brackets. Below is a picture of the flap torque tube bracketed in from the other side: I had to drill out the six rivets that mated the control tube brackets to the main spar. Below shows the positioning of the autopilot brackets: With everything out of the way, the two side brackets can be set with a pneumatic rivet gun. The center ...