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| N2C is Complete...Not Yet Assembled |
It is now the summer
of 2010. I started this project back in October of 2005. I am in the home stretch, in fact the airplane is
now complete and construction is over. What remains is paint prep, paint, assembly, fuel flow test, weight & balance,
taxi test and then flight. If all goes according to plan this airplane will be in the air before the end of July, 2010.
If there are snags, which there usually are...Labor Day is my outside date. I currently have about 1600 hours of logged
construction time. I am very inspired by other Bushcaddy Builders that I have come to know through this process.
The latest news besides the airplane being complete is I have bought a hangar at KPYM, Plymouth, MA. It's a true
man cave, furnished, wall to wall carpet, insulated and heated. Final assembly will take place there. The Glastar
Sportsman cowl that I had to order so that I could accomodate my Powerflow Exhaust system, was very complicated to install
and it took me quite a while to get it right. The end result is outstanding and gives the nose a bit of a different
look. 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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| Prop On. Debbie enjoys some wine at the hangar. |
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| My New Hangar at KPYM, Plymouth, MA |
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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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| Glareshield Complete |
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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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| Windshield Installed...A Lot Of Work... |
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| Panel Wired & Complete |
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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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