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| Windshield Installed...A Lot Of Work... |
It is now the winter of 2010.
I started this project back in October of 2005. I thought it would take me three years and I'm well past that.
I currently have 1466 hours of logged construction time and I would say at least another 500 hours scratching my head or doing
research so that I do things right. The internet continues to be my best friend with a limitless amount of good
information out there on how to get things done properly. I continue to be inspired by other Bushcaddy Builders who
have climbed the mountain and flown their own airplanes. I know that I will finish sometime this spring, so there's
no panic, just a steady and persistent pace to the finish line. Right now the engine is in, the instrument panel is
in and the wiring is complete. I have to build the cowl, paint it and then fly it. The cowl has its
own problems due to the size of my Powerflow exhaust. I have ordered the cowl/nosebowl for a Glastar Sportsman, which
I know will accomodate the exhaust. I had to order the entire thing but will use only the front section of it...so there
will be further trials and tribulations. I have learned to be patient. It's been a great journey so far. Although amazingly
frustrating at times, building this airplane has been a great personal experience. The sense of accomplishment is huge
and I have learned a lot about myself...mostly positive:) There is a great group of people building these BushCaddy's
and I know I have made some lifelong friends...even picked up a few words of French!! An hour here, three hours there....persistence is the key to progress in
the Airplane Factory. See the Construction Log for the daily blow by blow.
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| Wiring Is Complete & So Is My Electrical Schematic...Finally |
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| Black Polyurethane Sealant is used to fill the gap between the wing tip and the rubber U channel |
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| Windshield Installation Materials, also need Black, Paintable Polyurethane Sealant |
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| Windshield Test Fit |
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| GPS Wiring |
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| Music Jack, no metal to metal connection at the panel |
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| Variable Power Supply |
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| Avionics Tray & Wiring Harness |
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| Tom Hassie, EAA Tech Counselor |
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| Strobe Wiring |
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| Panel Warning Light |
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| Master Contactor |
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| Wiring Spaghetti |
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| Mixture Knob Installed |
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| Drop Down Fuse Panel in Closed Position |
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| Mic & Headset Jack Installation |
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| Torque Tube Cover |
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| A Look Behind The Panel |
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| Cabin Interior Panel |
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| Landing Lights...$35 on Ebay |
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| Wiring... |
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| RG400 Coax Tool |
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| Antenna Cable Step 3 |
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| RG400 Coax Tool |
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| Aileron Trim; Safety Trim System Complete |
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| Aileron Trim |
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| Strobe Driver Box |
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| Preparing Radio Stack |
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| Cutting 2 1/4" Holes In Panel |
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| Flap Push Pull Mechanism |
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| FWF, EGT & CHT Probe Wiring |
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| Manifold Pressure Sensor |
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| Proper Tools Are Required |
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| EFIS Wiring Harness |
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| Pressure Testing Hoses |
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| Oil Pressure Hose Fitting |
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| Oil Cooler Hose Fitting |
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| Rudder Cables |
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| Joe Dalton, tours the Airplane Factory and gives a thumbs up!! |
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| New Cabin Heat Box |
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| Cabin Interior Painted Ag Cat Gray |
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| Moved Fuel Pump To Primer Branch Line |
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| Mixture & Throttle Cable Brackets |
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| Throttle Cable Bracket |
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| Lycoming O-235 L2C installed Feb 2009 |
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| Wings On!!! Last week of June, 2008. |
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| Hydraulic Landing Gear w/ 8x6 Tires |
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| Lycoming O-235 L2C, Superior Millenium Cylinders, Powerflow Exhaust |
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| Aileron Cable w/Nicopress Fittings |
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| Getting Seats Ready |
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| Left Wing Complete |
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| Aileron Actuator assembly |
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| Flap Actuator Access Cover |
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| Flap & Aileron Complete |
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| Left Aileron Hinge Bracket |
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| Jabiru 3300, Nicely Crated and Secure |
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| Jabiru 3300, Firewall Forward Components |
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| Levelling The Ribs |
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| Attaching The Aileron Hinge Brackets |
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| Flap Push Rod Tube Attachment |
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| Finishing Aileron Attachment Area |
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| Strut Attachment Bracket |
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| Before installing the windshield the areas under it must be painted first. |
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| Windshield Door Jamb |
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| Control Stick |
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| ANL 60 Current Limiter |
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| Fuse Panel Labeled |
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| Strobe Wiring |
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| Avionics Deep Reach Screwdriver |
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| Strobe Switch Wiring |
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| Panel Warning Light Wiring |
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| Master Switch Panel |
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| Testing The Sequence On A Switch |
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| Fresh Air System |
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| Mic & Headphone Jack Wiring |
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| Oil Cooler Shutter Cable |
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| Camloc Added to Drop Down Fuse Panel |
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| Mic & Headset Jack Installation |
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| Fuel Sight Gauge Installed |
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| Left Side Interior Panel |
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| Landing Lights |
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| Wiring... |
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| Antenna cable Step 1 |
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| Aileron Trim; Safety Trim System |
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| Aileron Trim |
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| Preparing Radio Stack |
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| 2 1/4" Panel Holes |
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| Flap Push Pull Mechanism |
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| More FWF Wiring |
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| Fuel Pressure Sensor |
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| AFS 3500 Shunt |
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| Testing Harness For Continuity |
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| Enerpac Hydraulic Hand Pump |
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| Engine Breather Hose |
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| Parking Brake Installed |
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| Joe, Gets To Help Make a Small Aluminum Box, to put his secret stuff in. |
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| Triangular Heat Box Takes Up Less Room |
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| Primer System soldered fitting |
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| MA-3PA Marvel Schebler Carb Overhauled by Avstar in Jupiter, FLA |
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| Plane Power 60 Amp Alternator & SkyTec Flyweight Starter |
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| New Fuel Pump Location |
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| Throttle Cable Bracket |
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| Aileron, Sprayed With Coloado Red |
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| Landing Gear Strut Components |
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| Strut Reassembled & Safety Wired |
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| Zero Time Engine |
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| Flap Handle |
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| Fuel Selector Valve |
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| Right Door Complete |
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| Left Wing - Bottom Skin Riveted, Pitot Tubes Ready |
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| Flap Actuator Connection |
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| Setting Up For Wing Washout |
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| Left Wing - Stringers Complete |
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| Avionics Pre-Wired By Stark Avionics |
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| Right Wing Goes To Hangar |
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| Flap Skins & Hinge Arms |
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| Spar Wing Attachment Bracket |
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| Flap End |
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| Pulling In The Leading Edge |
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| My Friend Ray (left) Helps With Solid Rivets |
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| Rubber Butyl Tape is used along the top of the fiberglass retainer |
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| Windshield Roof Connection |
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| cabin Ceiling and Hand Holds |
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| Glareshield Access Panel Holes |
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| Fuel Line To Carb...Finally I'm Happy |
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| Antenna Doubler |
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| Audio Wiring |
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| Strobe/Position/Nav Light...LED |
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| Cabin Light |
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| Drew Thwaits My CFI Visits The Airplane Factory |
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| Master Switch Wiring |
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| Safety Trim Switch |
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| Hi Lo Voltage Sensor |
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| Carb Heat Handle/Cable |
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| Custom Throttle Knob |
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| Non Conducting Shoulder Washer used for Mic & Headset Jack Installation |
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| Soldered Mic Jack |
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| Seat Belt Brackets |
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| Lower Left Panel Connection |
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| Landing Lights Mounting Doubler |
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| Wiring... |
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| Antenna Cable Step 2 |
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| Panel Radio Stack |
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| Panel, Carbon Fiber Overlay Covered In Tape |
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| Flap Push Pull Mechanism |
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| Flap Handle & Push Pull Cable |
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| FWF Wiring |
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| EGT Terminal |
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| Timing The Magnetos |
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| Primer Distribution Fuel Line |
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| Oil Cooler Hose Mounted |
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| Fuel Selector & Parking Brake Finalized |
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| Hand Holds fabricated for the cabin ceiling for thsoe rough days!! |
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| GreatTool!! Lenco, Model 840 Swedge-On Tool. $8.95 at www.weldingsupply.com |
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| Crimped 6 AWG Alternator Cable |
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| Primer System Distribution |
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| Looks Brand New...A Work Of Art.... |
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| Case Mount Bracket for Alternator |
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| Parker Primer System Solenoid Valve Activated by Monentary Switch on Panel. |
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| Mixture Cable Bracket |
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| Aileron Hinge Bracket Actuator |
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| Elevator....Painted Up. |
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| Rigging Ailerons On Wing |
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| L to R: Don, Ron Cooper/Engine Builder, Rob Irvine/BushCaddy Builder |
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| Flap Actuating Mechanism |
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| Fuel Line, Co-Pilot Side |
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| Right Door Interior View |
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| Right Door Open Position |
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| Left Wing Leading Edges Cinched In |
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| Left Wing, Top Skin Riveted |
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| Aileron Jigged For Drilling Skins |
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| Garmin SL40, Garmin GTX 327, PMA 4000 Audio Panel |
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| Right Flap Complete & In Position |
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| Flap Actuator To Hinge Arm Attacment |
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| Right Wing Rib Layout |
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| Aileron Push Rod Tube |
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| The Wires In The Bare Hole Are There Temporarily |
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| Skin Riveted, Looks Great |
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| Fuel Tank, Held w/Nutplates, Complete |
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All Metal, Wheels, Floats Or Skis, Robust
Bushplane
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