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
15 & 16 Nov 2025
This post is from Gary's Sling TSi