Don's BushCaddy R-120, The Skunkworks Airplane Factory, N2C

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This section is a Reference Library for documents, articles and other materials I have found useful.  First is a link to the FAA website which has the entire edition of 43.13 Acceptable Methods, which should be every homebuilder's bible.  There is also a Canadian version of this I do not have, but I think they are very close in content.  The Skunkworks Reference Guide, is a two page synopsis of very useful information that you should post in your shop as, I guarantee, you will refer to it all the time.  Also listed are other informative articles/documents.
 

Advisory Circular 43.13 Acceptable Methods, Techniques And Practises - Aircraft Inspection And Repair:

 
 
The Skunkworks Reference Guide has a little bit of everything: drill bit sizes and decimal dimensions, torque values, rivet designations, max amp rating per wire gauge, etc., etc.  Print this and post it on your shop wall, you will refer to it all the time:

Skunkworks Reference Guide

 
 
This is a PDF version of my Electrical Schematic which was developed with lots of help and input from many.  I did a lot of research on the Aeroelectric Connection and embraced many of the principles recommended there.  I used Microsoft Visio to create the drawing, if you want the Visio version just email me and I'll send it along.

N2C Electrical Schematic

 
 
You will often be trying to determine what rivet to use in a certain application.  The plans are very good about identifying which rivet goes where but you'll be making changes and doing some things differently, so it's always nice to know that you are using the proper rivet for the thickness of the material you're working on.  Print this out and keep it on the shop wall, I use it a lot.

Avex Rivet Grip Range

 
 
These next two items are very handy.  A guide to AN Bolt Dimensions that lists the grip and length for every size bolt you will encounter.  Second is a chapter from the Coast Guard Sea Cadets text book on Aircraft Hardware that is very informative:

AN Bolt Dimensions

Aircraft Hardware

 
 
It's not easy to drill out solid rivets without enlarging the hole.  Vernon Little is a Canadian RV-9A builder who has a pretty good method, which should limit the damage.

Drilling Out Solid Rivets

 
 
Full credit for this type of Sight Gauge has to go to Bearhawk Builder, Peter Stevens, from Utah.  I did modify them to fit the Bushcaddy, and also added a few other things that make them a little more user friendly.

Sight Gauge Instructions

 
 
Here are two excellent articles from the EAA Library.  One by Ron Alexander on Hardware, again very informative and the other by Tony Bingelis on Safety Wiring.  Tony is the author of several books for homebuilders and perhaps is best known for his Firewall Forward and Engines books.  Although somewhat dated as they were written prior to the advent of the internet,  nevertheless, they are loaded with good information regardless what engine you plan to install.  Anyway, here are the two articles:

AN Hardware, EAA Article By Ron Alexander

Safety Wiring. EAA Article By Tony Bingelis

 
 
Here's a good manual on how to attach coaxial cable to BNC fittings.  Good info for antenna and comm cables.  This document was provided by fellow builder, Marin Streeter.

Coaxial Cable Instruction Manual

This is a very cool weight and balance graph.  For the R120 and R80 leave the values in blue alone and change the values in yellow to match your airplane.  For another type of airplane you must know the Arm and Moment numbers for your plane and change the blue values accordingly.  You can drag the graph to the side by clicking in the upper right area of the graph.  This will expose the values for the axis and you can change those to match your envelope, then drag the graph back.  Good luck with it.

Bushcaddy R120 Weight & Balance Graph

You need to figure out where to solder the wires for the Mic and Headphone Jacks.  This very helpful picture shows what goes where.  Basically you will have an Audio HI and Audio LO.  The LO always goes to the "GND" or "Base" and the HI goes to "Tip" or "Ring".  Typically the PTT wire for the Mic Jack does not need to get run to the jack, it would go to the PTT lead coming out of your wiring harness or radio.

Mic & Headphone Jacks

All Metal, Wheels, Floats Or Skis, Robust Bushplane