South African manufacturer The Airplane Factory has built a four-seat kit aircraft from kit to flight in only four days.
Known as the Sling 4-4-40 challenge, the aim was to build a Sling 4 in four days using 40 workers.
The build, which normally takes a kit builder 1000 hours to complete, took place at the 2014 Africa Aerospace and Defense Expo at the Waterkloof Air Force Base 17-21 September. The team consisted of highly skilled workers, and even some marketing, admin and catering staff.
The team worked around the clock, with the day and night being split into 10 and 14 hour shifts respectively. This his how they did it.
Day 1: centre and rear fuselage constructed and joined, gear and undercarriage assembled, Rotax 914 ULS was wired and made ready for installation. The night crew then got the fuselage on its wheels, engine and propeller mounted, and wings three quarters of the way complete.
Day 2: work continued on wiring the engine and panel, installed the ballistic recovery parachute, and the wings and empennage nearly completed.
Day 3: Sling 4-4-40 was rolled out of its build area, both wings were attached, landing and strobe lights connected and working, and avionics fired up.
Day 4: All components finished, completed a dual inspection and filled in the final bits of paperwork.
The aircraft was on display at the show before being flown back to The Airplane Factory's home base.
This effort surely eclipses that of Zenith, who built a CH750 Cruzer in one week at Oshkosh this year.