8 Sep 2024

I am recreating the ducting system for the fresh air / heater HVAC connection below the dashboard. My modifications to the original Sling design did not work - despite various attempts to seal the Sling components, including excessive amounts of Flame Master sealant, they continued to leak air. I've bought some replacement T pieces from Vans Aircraft (VA-175) and Aircraft Spruce which are far sturdier, easier to seal and look better too. I also bought some 2" aluminium flanges. I trimmed the flanges by about 15mm, and took about 10mm off the side legs of the Vans T-pieces. This brings the T piece more in line with the Aveo air vents in the dashboard. The expanded ends of the T's fit over the air vents on one side and the other T fits into the back end of that and onto the flange.

I cut the original Sling side duct channel slightly shorter to remove the original ducting, then drilled new 50mm holes (one on each side) to accommodate the trimmed flanges. The next step is to create the new flexible ducts to fit between the inner and outer skins to route air to the rear passengers.