My Sling TSi Airplane Build Walkaround Video

[edwardb]

Many on here know I've taken a time out on car builds and am building an airplane. Really interesting project so far which I'm enjoying a lot. Surprising number of similarities to a Factory Five build. Discussions among builders about upgrades, backordered parts, errors in the manual, builders posting questions that are explained in the manual (:p), etc. But obviously a lot of differences too. No discussion about too many Clecos. More like I have multiple hundreds and still run out. No discussions about pulling rivets by hand. I don't have a count. But thousands. And the Factory Five .040 thick aluminum seems heavy duty in comparison. The airplane is mostly .018 and .020 thick.

Anyway, today I did a walkaround video that maybe some will find interesting. BTW, still checking the forum daily (or more), posting, and answering PM's.


https://www.youtube.com/watch?v=YWg9f22SSC4&t=17s&ab_channel=PaulBorror

[Namrups]

Very impressive! After following your coupe build I convinced myself that I could also build one and I have. But I have to admit that I will not be building an airplane. You are way out of my league with this. Keep us posted as you reach the finish line.

Scott

[Andrew Davis]

Enjoy the build. As a long time member, may I suggest an EAA membership. Good folks and a valuable resource.

[edwardb]

Enjoy the build. As a long time member, may I suggest an EAA membership. Good folks and a valuable resource.

Thanks. Agreed. I am a member. The link to my build website noted in the video comments (https://eaabuilderslog.org?s=PaulTSi) is provided by EAA.

[cc2Arider]

Looks good Paul!

Nice work, as always :)

Did you have to bend, cut, and/or shape any of the other support panels? I noticed quite a few flared holes. Did you have to form those?

Craig C

[Cincy123]

Nice work Paul. Do you get a chance to fly much in the winter months?

[edwardb]

Looks good Paul!

Nice work, as always :)

Did you have to bend, cut, and/or shape any of the other support panels? I noticed quite a few flared holes. Did you have to form those?

Craig C

Thanks. No bending or cutting. The precision as provided is amazing. The majority of the shaped parts, e.g. wing and empannage leading and trailing edges, the curves visible in the video around the bottom of the fuselage, etc. are all completed at the factory. Again, the fit is excellent. There are a very small number of parts that are provided flat and they are bent as you install them. Like the rear fuselage top skins that aren't installed yet. The skins are provided flat. But they curve around the bulkheads as you install. Because of the thickness of the material (thin...) and the soft curve, not difficult.

The second part of your question is actually what's called dimpling. Most of the material used is too thin for traditional countersinking. So anywhere a flush rivet is used, the material is dimpled. Basically stretches the aluminum to create a countersink "pocket." Including any underlying layers so they all fit together. Where the layers attach to a solid structure, e.g. the wing sheeting along the wing spars, the spar solid structure has a regular countersink. Everything else dimpled. Pretty interesting how it all works and as I understand pretty standard aviation practice. On the video, the front approx 1/3 of the fuselage is flush rivets so the skin had to be dimpled. On the wings and empannage pieces, high percentage of flush rivets. So lots of dimpling there too. There were a handful of small pieces with factory dimpling. Balance is part of your work as the builder. Some of the big sheets, like the wing skins, are interesting to handle. The build manual has diagrams of where dimples are required on all the pieces. The tool used is this one. With various dies for the different rivet sizes and angles.

https://hosting.photobucket.com/images/ab234/edwardb123/IMG_3128.jpg?width=590&height=370&fit=bounds (https://hosting.photobucket.com/images/ab234/edwardb123/IMG_3128.jpg?width=590&height=370&fit=bounds)

[edwardb]

Nice work Paul. Do you get a chance to fly much in the winter months?

Thanks. I haven't mentioned it here. But I did back when I talked about an airplane build. I’m not a pilot. A few hours of training including a logbook with my son listed as the CFI which I’m very proud of. But I never completed anything and don’t expect I will. So, what am I going to do with this thing when it’s done? Again, I don’t have the final answer. I’m doing it because I’ve always wanted to and I love the build process. That’s enough for now. I would love to keep it in the family. But I haven’t gotten a clear signal from my son that he’s going to fly in it. A career in certified airplanes and now a professional safety manager, he has some reservations about experimental. Even though the Sling TSi, by all accounts is a robust and very safe airplane. Plus, it will be very carefully built. But I understand. It definitely would be sellable, so that’s an option. So is possibly donating. We’ll see when the time comes.

If you're really bored, the complete post is here: https://thefactoryfiveforum.com/showthread.php?45961-My-Journey-to-the-Next-Project-Sling-TSi-Build&p=524707&viewfull=1#post524707

[Dieter123]

Paul, I am currently an FAA FSDO Airworthiness Inspector in Wichita. Grew up in a nearby town of Lake Orion (Shelby Township). Nice work so far. If you haven't already, I would reach out to the local Flight Standards District office and give them a heads up. Not sure if it would be the Detroit or Grand Rapids office. Keeping them in the loop and understanding what they will be looking for when the time comes for Certificate issuance and Registration. I know that having personnel build logs is something they would be asking for when your are ready.

[edwardb]

Paul, I am currently an FAA FSDO Airworthiness Inspector in Wichita. Grew up in a nearby town of Lake Orion (Shelby Township). Nice work so far. If you haven't already, I would reach out to the local Flight Standards District office and give them a heads up. Not sure if it would be the Detroit or Grand Rapids office. Keeping them in the loop and understanding what they will be looking for when the time comes for Certificate issuance and Registration. I know that having personnel build logs is something they would be asking for when your are ready.

Thanks for your comments. Much appreciated. I have a full package of instructions and documents from EAA for that process. Plus I'm working with a build center here in Michigan (2 hours away) where I've attended a couple workshops. The plan now is paint and final assembly will be there. They have a DAR they work. They deal with the FAA processes so really counting on them. All I've done to date is reserve my N number. I'm documenting everything in written logs and pictures. Plus recording work time using an app on my phone. Think I have it covered for now. But we'll see. Knowing the little I know now about what it takes to get an airplane legal, kind of puts what we have to do with our car builds in a different perspective.

[gbranham]

When I was building my MkIII back in the early 2000s, a good friend was building a Van's RV-6A. We'd both come to work on Monday, swapping build stories from the weekend, and the builds did have a lot of similarities...and a lot of the same knuckle and hand scrapes/bruises, etc. I have thought for years that I'd like to build a Sonex-B. Maybe some day.

[WIS89]

Paul-

As usual, I look forward to following along with your build!

I am very excited to see you put this together. With your attention to detail and myopic focus, I am certain she will be a beautiful airplane. We need to have a chat with your son; shocking to hear his reticence to pilot this! I can't wait to see someone put it through its paces...

Keep up the great work, and thanks so much for your willingness to share this with us! I would say good luck, but frankly, you don't need it. Instead, I will say give it heck!

All the best Paul!

Regards,

Steve

[JimStone]

Always love reading your posts Paul, no matter what you're building. Thanks for remembering your Factory Five brethren!

[edwardb]

Another walkaround video. This time with a rather important addition to the build.


https://youtu.be/6lFWvDLs_Es

[JimStone]

Awesome! Such precision work required. Makes me nervous just looking at it.

[Higgybulin]

Over 1400hrs, well at least we know your keeping busy!! Right in your skill set wheel house! Looks good Paul!
Higgy

[edwardb]

For those following my Sling TSi airplane build, here's another walkaround video. It's basically as far as I can take it in my home garage/workshop. Next step is to a build center where it will get final assembly, paint, and all the steps to be airworthy.


https://youtu.be/TMSVOaqWyAQ

Probably not the right audience, but who knows? Throwing this out there: I've decided to try to sell the Sling TSi build project at this stage. Here’s a chance to take a completely built TSi over the finish line. Your personal paint scheme and any added options. Available immediately in SE Michigan, USA. No need to wait. Not an unexpected outcome from when I started a couple of years ago. But this is the fulfilment of a lifetime bucket list item so no regrets. Now it’s time for someone else to take over this carefully built beauty. This is my first airplane build. But I’m a long-time aviation enthusiast and multiple car builder. Very little about the content, terminology, methods, or tools were new to me. Built at home in my oversize garage and basement shop where it’s currently located.

Specifics: Sling TSi flat kit serial number 445sk. Registered as N920PB. Clear with bill of sale on hand. I received the first kits on April 4, 2023. Several additional shipments since then with everything 100% received and no missing or back-ordered parts. Rotax 915iS engine serial number 10003177 and Airmaster prop. The 916iS was released after my order and substantial parts received. I investigated a change but decided against the additional $20K cost. The 916iS is nice and basically a requirement for the HW. But the TSi remains an outstanding performer with the 915iS. Witness the hundreds worldwide. Similar discussion for the Airmaster prop versus other options that are now available.

For the build itself, the wings and empennage are 100% complete. The fuselage is essentially complete including all interior finishes and carpeting, cowl fitted, etc. Remaining is paint and details at the time of final assembly. All rivets are filled. All nutserts installed with JB Weld. All applicable Sling TSi bulletins addressed and documented. Has Midwest Panel Builders panel and harnesses with the full Garmin advanced IFR configuration including dual G3X Touch panels, G5 backup, GTN 650Xi navigator, XM, VPX, CO detector, LEMO jacks, VOR antenna, and IntelliKey. Pre-wired for the Aerospace Innovations Intelligent fuel boost system. EarthX battery and charger. Does not have a parachute although parachute cables are installed so one can be added. I chose not to prime or treat the 6061T6 aluminum due to its natural corrosion resistance.

Upgrades include upsized Matco brakes, upgraded and additional insulation, PTFE fuel lines (no 5-year replacement), Aerospace Innovations NaviFlow Fuel Manifold, heat/ventilation system modified for fresh air on top and heat on the bottom through SCAT tubing. I have details of everything, receipts, an electronic build log with dates and hours, KAI’s have each page annotated, dated, and signed, hundreds of pictures, and a build log on EAA’s website at https://eaabuilderslog.org?s=PaulTSi.

The build is planned to go to Midwest Sky Sports for paint and final assembly. By offering it for sale now, the new owner can choose their own colors and scheme or take it elsewhere if desired. If additional options are desired (oxygen, parachute, etc.) this would be an ideal time to add them. If it doesn’t sell now, I will proceed to completion and airworthiness. But ultimately it must sell. Note: The three outstanding SB’s on the engine are NOT closed. These must be completed under warranty by an authorized Rotax service center.

If interested, PM me and we can take the discussion off-line. Please, serious inquiries only. I’m not listing the price here. We can discuss it. The significant value will be there based on price increases and what you would pay for a quick build or a build center. Plus, you would likely save time over other options.

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[JimStone]

I'm not in the market for an airplane, but if I was I'd absolutely trust your work and meticulous attention to detail. The plane looks amazing. I can't believe that can be built in a garage.

[Aleinsteingenius]

is that an RV3? We have restored many antique planes here. Also members of the EAA. We built a very modified Sea Hawk amphibian experimental as well (8700 hours of work ugh). Now I am just starting a Mark V roadster. So doing what you are doing in reverse lol.

[edwardb]

is that an RV3? We have restored many antique planes here. Also members of the EAA. We built a very modified Sea Hawk amphibian experimental as well (8700 hours of work ugh). Now I am just starting a Mark V roadster. So doing what you are doing in reverse lol.

It's a Sling TSi. Says so in repeated places plus my narration in the videos. From Sling Aircraft in South Africa and distributed in the U.S. from Torrance, CA. Some similarities to several of the Vans (RV) models. But also quite a few differences. Sling has nowhere near the volume of Vans but is currently a very popular and in demand experimental homebuilt.

[Aleinsteingenius]

Looks like you are doing a great job. Here we are lowering the amphibian into my swimming pool to make sure it would float.213824