Sling 4 build Morningstar

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Sling 4 build Morningstar

Unread post by checkride » Thu Nov 05, 2015 8:52 pm

Hi All,

Big happenings for me and my son. Started our Sling 4 build yesterday. inventory is done so we started on Page 1 of the Empannage. By the end of today managed to de-burr all the bits and pieces for the horizontal stab. Tomorrow want to take some time out and finish the spray booth and finish the skins.
Ok so forgot to mention, this Sling will have a Jabiru 3300 engine installed ( 3 reasons - 1 not a lover of Rotax, 2 I know jabiru engines 3 cost. The upgrades add about 100 K to the price of the engine ) with the following features: LCH, EFI, Turbo Charged, inter-cooler and possibly Electronic ignition with advance / retard. All upgrades except the heads will be supplied by Edgeperformance in Norwegian . We already have the EFI running on our jab with great success, performance increase of 7% on Mogas. The electronics is supplied by SDS, this already has the feature for electronic ignition modules gone will be the old distributors. Prop is a 60" 3 Blade constant speed unit supplied by AX sport in Cape Town. We have this on our Jab right now and its great.
Turbo will be controlled electronically can be setup for boost or normalizing - Recommended boost around 38" .
150HP at really low boost and 160HP @ moderate boost. 168CHP at 3300rpm/44" map - 5min
156CHP at 40"
140CHP at 35"
125 HP continues

Thomas has these little turbo's running on the 4 cylinder engines with many hrs of problem free running. ...http://webshop.edgeperformance.no/index.php
https://www.facebook.com/edgeperformance.no/
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Last edited by checkride on Thu Nov 05, 2015 11:43 pm, edited 5 times in total.
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Re: Sling 4 build Morningstar

Unread post by cage » Thu Nov 05, 2015 9:46 pm

That bottle of Jack is looking a little sad ;)
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Re: Sling 4 build Morningstar

Unread post by checkride » Thu Nov 05, 2015 10:40 pm

whahahahah is has Benzine in it mate
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Re: Sling 4 build Morningstar

Unread post by checkride » Fri Nov 06, 2015 9:04 pm

Deburred all the parts for the Horizontal stab, then had to do it properly today, big learning curve. Did some work on the spray booth. Hopefully tomorrow can get the top and side finished. Just a frame from Batons covered with nice clear thick plastic, should be OK.
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Re: Sling 4 build Morningstar

Unread post by FLYGUYS » Sat Nov 07, 2015 11:17 am

Awesome stuff, keep us posted on the progress.
Good luck with the build :D :D
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Re: Sling 4 build Morningstar

Unread post by checkride » Mon Nov 09, 2015 11:17 pm

Sunday 8 th November.

4 hrs building the spray booth .
2 hrs cleaning scotchbrite and de-burring.
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Last edited by checkride on Mon Nov 09, 2015 11:27 pm, edited 1 time in total.
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Re: Sling 4 build Morningstar

Unread post by checkride » Mon Nov 09, 2015 11:24 pm

Monday 9th November:

Gleco the Horizontal stab and match drilled with 3.2 mm bit. This stops the skins from forming a wave or ripple. I know its not necessary but seen it been done with great success . Tomorrow will disassemble de-burr, clean prime and complete the horizontal.
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Re: Sling 4 build Morningstar

Unread post by checkride » Tue Nov 10, 2015 6:07 pm

Bit of a slow day today, etched primed the horizontal stab and de-burred. Tomorrow is prime and construct plus start on vertical Stab
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Re: Sling 4 build Morningstar

Unread post by checkride » Thu Nov 12, 2015 8:35 am

11 November 2015:

5 hrs

Match drilling the vertical Stab, disassemble de-burr and make ready for Etch and Primer. primed the Horizontal but didnt finish, spray guns messed up plus spray booth leaks need to sort that out before i have this stuff everywhere.
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Re: Sling 4 build Morningstar

Unread post by checkride » Fri Nov 13, 2015 7:21 pm

So last night we sealed up the spray booth and finished preparing everything for spray. So the pictures show the result of Anodising and also the end result using a etch primer.

This is my process:

1. Check my parts list
2.Construct the part e.g vertical Stab
3. Match Drill.
4. Disassemble to debur and Scuff all parts.
5. Clean with Acetone - Anodize 5 min in the bath remove and flush with water - dry
6. Clean again with Acetone before spraying with Etch Primer.
7. Construct - rivet.
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Re: Sling 4 build Morningstar

Unread post by checkride » Fri Nov 13, 2015 7:29 pm

This is the bath of Anodising solution. Some tools used during the prep faze . Some new tools arrived , 3.2 and 4 mm chuck reamers used to clean out a hole specially when one is busy riveting and the rivets are a bit difficult to go in.
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Re: Sling 4 build Morningstar

Unread post by checkride » Sun Nov 15, 2015 8:10 am

14th November - 6 hrs

So today we completed the vertical Stab and Horizontal stab.

1. Construct - Cleco all check fit and remove every second cleco
2. Mix some Strontium Chromate
3. Insert Rivits in holes and rivit
4. Remove Cleco's and rivet remaining to complete structures.
5. Photo's

Completed , cleaned up and make ready for elevators.
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Re: Sling 4 build Morningstar

Unread post by checkride » Sun Nov 15, 2015 8:18 am

Ok,

So some additional pictures of the inner structures showing the priming. The dipping of the rivets wet worked out good . It also helped as we had to clean out every hole for a nice fit of the rivet. All this prep work paid off as there are no ripples in the skins everything went together really well. This 4 mm and 3.2 mm chuck reaming tool was the best tool during this construction process.
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Re: Sling 4 build Morningstar

Unread post by checkride » Tue Nov 17, 2015 6:36 am

Didnt get much done today besides the Trim Tab, today will work on the elevators.
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Re: Sling 4 build Morningstar

Unread post by checkride » Tue Nov 17, 2015 7:58 pm

Today prepared the parts for the Elevators took the best part of the day de-burring scuffing and cleaning. Tomorrow we anodize , prime and construct
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