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

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Don's R-120, On The Gear, 11/06

I never met anyone....building any airplane, that didn't enjoy sharing the experience.  If you are building a BushCaddy and haven't sent me a few pics and some contact info, pls do so, we're all in this together and we can learn a lot from each other.
 
The purpose of this page is to highlight other BushCaddy Builder's projects and perhaps any changes or things done differently.  Anyone out there, trying to figure out if they:  want to build an airplane, have the skills to build an airplane or are just plain curious about airplanes, should feel free to contact these guys and take a look at their project; ask some questions and figure out if this is for you.  You'll find out that these guys are no different than you...they just got going. 
 

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Cabin & Fuselage Complete

Sylvain Papillon and his wife Chantal are building an L 160.  Sylvain & Chantal live in Sorel-Tracy, Quebec, which is in the Montreal area.  They started building the airplane in the fall of 2007.  They have made great progress as the fuselage and cabin have been completed and attached.  Sylvain also had his first inspection bt the Transport Canada folks and all went well.  Note the nifty maneuvering landing gear.  Much easier to move the plane around in the shop. 
 
As of Summer 2008 this energetic building crew is basically, structurally complete which is an amazing accomplishment in 10 months.  The wings are also complete and stored away until mounting. 
 
Sylvain and another Bushcaddy flyer, Robert Lavigne came up with a great idea of adding bushings to the aileron and flap hinge brackets.  Makes perfect sense as this is an area of wear and this modification means they can be replaced without altering the bracket.  Pics are below.
 
Sylvain just received his engine and it's a beauty.  Made by Aeropsport in British Columbia, it's an O-360 with dual P Mags.  Absolutely beautiful.
 
Another nifty little modification that Sylvain has come up with is using eye bolts to anchor the rudder pedal springs. Check out the pic below, a C-187 spring was used on the left and a C-191 on the right.  You can adjust the tension perfectly with the eye bolts.
 
His cabin interior is almost complete, check out the sight gauges modelled after the Bearhawk gauges but made at home by Sylvain.

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Aerosport O-360

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O 360 With Dual P Mags

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Aerosport Lycoming O 360

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Cutting The Bushing

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Aileron Hinge Bracket Bushing

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Squeezing The Bushing In

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L160 Cabin Nicely Primed

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Eye Bolt Anchors Make Adjustment Easy

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Right Wing Complete

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Rudder Complete

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S&C Papillon L 160 Fuselage Frame

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Skylight Complete

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S&C Papillon L 160 Fuselage Ready For Rivets

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L-160 Fuselage Riveted

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Bob Forbes, L 164 Cabin & Fuselage

Bob Forbes lives in Brasher Falls, New York, that's fairly close to Montreal.  Bob is building an L164 which will be powered with a Mazda Rotary Engine.

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B Forbes Closed Loop Rudder System

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BForbes Closed Loop Rudder System

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B Forbes, Pitot

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B Forbes, Leading Edge Light

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B Forbes, Rotary Engine

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B Forbes, Wing Complete

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Great Paint Scheme!!

Marin Streeter, lives in Stanwood, Washington and is building an R-80 ELSA, which will be powered by a Jabiru 3300.  I have gotten to know Marin quite well since he started building and I'm counting on him to get ahead of me so I can follow his engine installation!!.  He has an affinity for the tools and plans like no one else I've seen.  I've told him BushCaddy should hire him to do their quickbuilds.  He is an airplane building machine.  Marin also uses Kitlog and has a Construction Log on the internet.  One of Marin's modifications was to change the door skins to Lexan for a "total" view.  I love the paint scheme.  Marin has used the water borne paint process from Stewart Systems.  You can paint with just a basic respirator...nothing special required.

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Jabiru Air Box

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Jabiru Air Ducts

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Jabiru Heat Muff

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M Streeter, Lexan Door

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M Streeter, Wing Ribs & Stringers

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R Beland, Fuselage Complete w/Epoxy Primer

Rene Beland, is building an R-80, is originally from Quebec and currently lives in Waterford, Wisconsin.  Rene has a Construction Weblog on the internet.  If you review his pics you will see that he is very detail oriented. 
 
Rene just recently decided to use Poly-Fiber Epoxy Primer on his plane.  Check out the pic above, it looks outstanding and he says it is a very hard finish.  It seems to have been relatively easy to do with the right prep work.

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R Beland, Fuselage

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R Beland, Bulkheads & Stringers

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R McNamara L-162 Cabin

 
Ron McNamara lives in Ottawa, Ontario, and is building an L-162.  He also has his engine, a Mattituck TMX, IO 360, 200 HP, with cold air induction, forward intake and flowed heads.  He will mount Clamar 2500 Amphibious Floats.  Looks great!!  This is Ron's 2nd BushCaddy, he also owned an R-120, GHSU, which you can see on the BushCaddy website as a tri-gear, he used it as a taildragger.

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Almost Ready To Fly

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Wings On

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R McNamara L-162 Cabin & Fuselage

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R McNamara, Mattituck TMX 360

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York Harbour, Newfoundland

 
Calv Swift, is from York Harbour, Newfoundland, which is on the west coast, near Corner Brook.  Looks like a beautiful area.  He just started building an R-80 in early 2007 and is one of three builders in the Atlantic provinces.

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Cabin & Fuselage Complete

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Cabin Frame Attached To Fuselage

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On The Gear

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Cabin Fame

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C Swift, R 80 Fuselage

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C Swift, R 80 Inside Corners

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Horiz Stab, Elevators, Rudder, Ailerons & Flaps ready to be closed up after Pre Cover Inspection

Wayne Burtney, lives in Acton, Ontario and is building an R-120.  It will be powered with a Continental O-200.  Wayne started his project in Feb, 2001 and has just successfully completed the Pre Cover Inspection.  This is a very big deal in Canada, where all components of an experimental aircraft, must be inspected by MDRA ( Ministers Delagates-Recreational Aviation ), prior to being finally riveted and closed up.
 
The inspector found only minor items like a burr on the end of a stringer and a solid rivet that needed some additional setting.  Wayne is also well versed in Corvair engines and in particular the addition of a fifth crankshaft bearing to that engine.

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Wing & Fuselage, Pre Cover Inspection complete.

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Rick Pewtress lives in Utah and is building an R-120.  Rick has worked on several Bushcaddy's and is very knowledgeable.  He is also building the Jabiru engines mounts for two builders - Marin Streeter in Washington and Stan Shannon in Texas.  Originally Rick was also going to build the engine mount for my Jabiru 3300, but after I switched gears and went with my Lycoming O-235 L2C, he made me a dynafocal engine mount instead.
 
Rick is pretty far along with his R-120 which will be powered with a Lycoming O-290 D, it is 140 HP with electronic mags, chromed cylinders, lightweight starter and alternator...that cut out 22 lbs.  Looks like he'll be flying in a few months.
 

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R 120 Cabin & Panel

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R 120 Lycoming O-290 D2

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R 120 Prop Installed

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J Birrell R 80 Complete & Flying

John Birrell, lives in the Beetaloo Valley in Southern Australia, and has completed and is flying an R-80, powered with a 90 HP Subaru engine.  He has several hundred hours on the plane to date.  I believe he is the only builder with a Subaru and is very happy with the result.  One of his modifications, after completion, was to add an aileron trim system.  Check out his installation in these pics, it seems very straightforward and according to John is extremely effective and helpful for flying a straight course, with rudder input only.

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J Birrell, Subaru Engine

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J Birrell, Aileron Trim

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J Birrell, Aileron Trim

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J Birrell, Aileron Trim

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J McKinley, Fuselage Complete

Jamie McKinley is building an R-120 and lives in Pennfield, New Brunswick.  I have stopped by and visited with Jamie several times on my way to Cape Breton.  Jamie's airplane was the first BushCaddy I saw.  After seeing the structure up close and personal I knew this was the airplane for me and I can tell you because I have seen it...Jamie's workmanship is top notch.   Jamie is also very involved with the Young Eagle program and was recently mentioned in EAA's Sport Aviation Magazine. 

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D Bonin, Cabin & Fuselage

 
Denis Bonin, is building an R-120 and lives in the Montreal, Quebec area.  Denis has modified a few things: he added a trim tab to the elevator which will be controlled via a push/pull cable, a Naca air scoop to the cabin area and fabrictaed his doors using a single piece of aluminum sheet...no seams.  He fabricated his own throttle set up and will add two skylight windows.  He has fabricated an aluminum box that matches the curve in the roof and will divide the skylights (glass not in yet).

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D Bonin, Elevator Trim Tab

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D Bonin, Ceiling Box, Skylights To Be Added

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D Bonin, Custom Throttle

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D Bonin Vert Stab Fairing

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R Pitts, Son Mark At The Controls

Rick Pitts, lives in Wasilla, Alaska and is building an L-164.  I believe he plans to power it with a Rotary Engine.  He is almost done with his wings but has been working long and hard on the cabin. 
 
Check out the aluminum diamondplate floor boards.  Also Rick added his own seats.  The front seats are from a Cessna and the jump seats in the back are really nice.  He got those from Atlee Dodge (www.fadodge.com), they are only about 5 pounds total and stow in an up position until needed.

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Jump Seats - Stowed Position

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Jump Seat - Down & Ready Position

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Cessna Seat

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Cessna Seat

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Aluminum Diamondplate Floor Boards

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R Pitts, Leading Edge Landing Light

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R Pitts, Wing Ribs & Stringers

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E Tremeer, Fuselage

Everett Tremeer, lives in Winnipeg, Manitoba and is building an L-164.  I like the jig he made for making sure Bulkkead 7 was square.  He plans to power the plane with a Lycoming O-360.

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E Tremeer, Bulkhead 7 Jig, Simple & Effective

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E Tremeer, Rudder Spar

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S Sapkos, L-162, Almost Ready For Flight

Stan Sapkos lives in Wickenburg, Arizona, he has finished building and has successfully flown his L-162.  His plane is powered with a Superior IO 360, 180 HP.  Stan's prop is an 80" Hartzell.  Stan got the Quick Build Kit and he  worked daily to get it together, he started 11/06 and flew the airplane for the first time 10/07.  Really nice paint job, interior and panel.  Fantastic and an inspiration.

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S Sapkos L-162 Cowl

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S Sapkos L-162 AirBox

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S Sapkos, L162 Nearly Complete

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S Sapkos, L 162

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S Sapkos, L 162 Panel

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S Sapkos, L 162 Almost Flying

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S Sapkos, L 162 Panel & Interior