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

Recent Photos & Updates

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Paint14.jpg
Aileron, Sprayed With Coloado Red

Well it's getting late in 2008 and it wasn't an overly productive summer/fall but I got everything accomplished that I set out to do during this period.  Summer is always a tough time in the Airplane Factory due to vacations and other obligations. 
 
But the wings got attached and rigged and that was a major success.  Along the way I also rigged the flaps, ailerons, jury struts and the cabin to wing gap seals.  All this accomplished at the Hangar at K28M Cranland.
 
While the fuselage was out of the garage, I took advantage of the space and started painting.  My paint is Ranthane, a two part polyurethane.  I applied it with a Graco 3800 HVLP system and also used a fresh air hood.  There was quite a learning curve on using the system and applying the paint but I am thrilled with how it all came out.  I was able to get all the control surfaces painted as well as numerous smaller items.
 
I just got the fuselage moved back to the Airplane Factory so all winter long I will be able to just walk out my door and go at it.  I expect it will be a very productive time.
 
I have a laundry list of items to wrap up before I install the engine and wire up the the instrument panel.  The first thing is to permanently mount the landing gear.  I disassembled the struts Rob Irvine made for me and had them powdercoated black.  Thely look great.  After the gear I need to finish up the cabin interior and controls...then it's on to the most exciting part...engine and instruments.
 
I now have about 1050 hours into the project and have passed the three year mark.  I originally thought I'd be done in three years but it will definitely be four...and maybe a bit more.  That's ok, I have learned some patience, it'll be done when it's done, there's no panic or a timetable on my end.
 
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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Aileron Hinge Bracket Actuator

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Elevator....Painted Up.

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Landing Gear Strut Components

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Rigging Ailerons On Wing

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Strut Reassembled & Safety Wired

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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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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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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

All Metal, Wheels, Floats Or Skis, Robust Bushplane