Gary's Sling TSi

21, 22 and 23 Nov 2025

Rotax metric fitting replacement, more wiring

Comet Aviation supplied the Rotax 916iS engine, but it came with metric rather than UNF fittings for the fuel and oil connections. An authorised AP was sent to replace the fittings so that I could proceed with using 6AN PTFE lines (21 Nov 2025). They advised that the governor needed to be rotated to permit full cable movement

Fabricated most of the firewall forward PTFE fuel lines and fitted them in place with fire sleeve

Fitted the oil lines supplied by Midwest to the oil tank and engine

Fabricated mounting brackets for the side skins to accommodate the CPC connectors for the wiring harness (Sling has enlarged the holes so the CPC connectors can no longer be directly attached to the side skins)

Trimmed the dashboard surround to suit the instrument panel using the aluminium template supplied by Midwest Panel Builders

Cut the right-side water hose to accommodate the interior heater T piece

Fitted the ground wire from the main airframe ground on the copilot's side to the ground bus on the instrument panel shelf

Fitted the engine ground wire from the main airframe ground to the earth point alongside the starter motor per the Rotax manual. This ground wire terminates at the same mounting location as the battery ground on the airframe

Tidied up some of the firewall side wiring

Drilled holes to suit the GA35 WAAS GPS antenna on the rear fuselage above the luggage compartment

Removed the propeller governor and rotated it one hole clockwise to achieve full travel for the control cable as advised by the A&P. Refitted safety wire, checked gasket orientation again, refitted to engine

Fitted connectors for exterior USB port in W2 connectors, fitted wires for fuel transfer pumps to W2 connectors, fitted GT150 connectors for fuel senders at the fuselage sides and transfer pump wires in the wing roots

Fitted heatsink for regulator B

Fitted water expansion tank hose

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15 & 16 Nov 2025

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