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Project: BushCat376WW -
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Categories

Show All Entries - (96)
Research
Workshop - (2)
Empennage - (3)
Fuselage - (30)
Firewall - (2)
Tail Feathers - (5)
Wings - (16)
Controls - (4)
Avionics - (5)
Lighting - (1)
Instrument Panel - (4)
Landing Gear - (2)
Engine - (11)
Propeller - (2)
Fuel System - (1)
Interior Finish - (2)
Paint / Decals - (2)
Inspection - (2)
Tools
Crates - (2)


Builder Name:	Mick Warning -

Project:	SkyReach--BushCat - VIEW REPORTS
Start/Last Date:	Nov 25, 2020 - No Finish Date
Engine:	Rotax 912ULS
Propeller:	Kiev 3-blade
Panel:	Kanardia/Trig

Friendly URL:	https://eaabuilderslog.org?s=BushCat376WW

Home or Last Project Picture

Aug 09, 2022 Done!

Category: Interior Finish

Today I added the document holder with the Airworthiness Certificate in the cockpit, so that officially means the plane is complete and ready to fly! Now we just have to get the pilot up to speed....

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Aug 06, 2022 inspection covers

Category: Interior Finish

Added the inspection covers on the sides of the control console, as well as the joystick boot.

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Jul 27, 2022 Engine is healthy

Category: Engine

Spent a couple weeks working with Rotax on my engine having a 700 rpm drop on one mag. Tried lots of tests including carb sync, kill wire swaps, eliminating external wiring, checking timing pulses, spark plugs, etc.... Figured it had to be one of the ignition modules, and it turned out to be the one right on the top.

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Jul 12, 2022 AWC day

Category: Inspection

Joe Norris (Designated Airworthiness Representative) came in today to see if the plane makes the requirements to issue the Airworthiness Certificate. He looked it over, snapped a bunch of pictures, and the deed was done!

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Jun 08, 2022 Weight and Balance

Category: Controls

Here's how the weight and balance are done.

Jacking up the wheels to slide the scale under.

Get the tail up so the plane is in level flying attitude.

Left wheel weight.

Right wheel weight.

Overall view of weight and balance in process.

50 pounds on the tailwheel.

Jun 07, 2022 Spinner

Category: Propeller

Pulled the protective coating off the windshield. Added the spinner.

Yes the plastic is clear under this white film.

Spinner goes on with 6 small bolts at the base.  Needed to remove the cowl to install it.

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May 23, 2022 Prop is on-

Category: Propeller

Kiev Prop (Ukraine) is on and pitched.

Pitch gauge attached to the prop.

The spinner fits.

May 21, 2022 VG's!

Category: Wings

Stuck on the vortex generators this morning. Nice having the plastic template provided in the kit so there is not a bunch of measuring to be done.

Sticking them on one at a time.

A wing full of VG's.

May 18, 2022 Wing Root Fairing

Category: Wings

Wing root fairings clecoed on. Pulling the rivets with a backing washer was much easier with the doors removed.

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May 16, 2022 Safety wiring turnbuckles

Category: Controls

Adding safety wire to the turnbuckles after tension adjustments are set.

Rudder turnbuckles in cockpit console.

Wiring in the wing takes some dexterity.,

May 15, 2022 Important sticker

Category: Fuselage

The white stripe is added across the top of the windshield to keep the wind from getting under the perforated vinyl on top and lifting it off. Then so it doesn't look like an add-on, you stick the BushCat logo on it.

White vinyl stripe to hold down the leading edge of the perforated vinyl.

Making it look cool with a logo.

May 14, 2022 Aileron/Flap setup

Category: Wings

Connected and adjusted aileron and flap linkage. Not much of a picture to take, since all it entailed is twisting on pushrods and turnbuckles in the wings and fuse. Added some more stickers, however! We now have an N-number and a pretty chrome/black advertising name on the nose.

N-number in place.  FAA says it must be at least 3" high and between the wing and tail.

Exposing the sticky side of the BushCat logo.

I think it's pretty-

Adjustable flap and aileron linkage on the outside of the wing.  Boring picture.

May 12, 2022 Stickers!

Category: Instrument Panel

Added the vinyl labels that came with the kit.

The plane carries an "experimental" license since it was amateur built.

I think the fuel goes here.

You are in the "no spin" zone.

The dorsal fin is a great place to rest your hand when standing by the plane....but don't do it!

May 09, 2022 door latches and dash attachment

Category: Fuselage

Added these crazy door latches to the front of the doors, I guess to keep them from blowing off during high speed runs. Also bolted in the dash, which took a good 2 hours. Added the labels to the dash so i know what all them buttons are for.

 Door open with latch clecod in place.

Door closed with latch engaged.

Bolting in the dash panel.

No dash labels.

With dash labels.

Apr 28, 2022 Aileron aerodynamic compensation system

Category: Wings

Fancy name for a couple pieces of aluminum riveted to the trailing edge of the ailerons. This system should take some of the pressure off the stick when banking for turns.

Drill and cleco first...

...then pop a few rivets.

Apr 10, 2022 Back at it--

Category: Fuselage

Weather is now warmer so it is tolerable to work in an unheated hangar. Maple sap/syrup season is over so time is available. Got to get my head back into working on the Bushcat. Tightened up 6 bolts in the cockpit now that the windshield is very permanent. Also installed the elastic bands to hold the covering together on the tail hinge lines. It's a start....

Upper aft corner of cockpit.

Tying elastic bands.

Feb 01, 2022 Waiting on warmth

Category: Fuselage

So there she sits just waiting on warmer weather for the final push.

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Dec 27, 2021 Door Latches

Category: Fuselage

Door latches are installed and the doors are on and secured for the winter. No other major assembly needs to be done. My list of things to do now consists of tensioning cables, instrument panel legends, and figuring out the ROTAX. And make sure all the paperwork gets done....

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Dec 15, 2021 Door latches

Category: Fuselage

Took advantage of the warm day and got Mark out to the hangar to help pull a dozen rivets and line up the door latches.

Mark showing off his new tool.  Used to add nylon washers to rivets in hard to reach places.

Mark's new tool in action.

Top of plane is all riveted up.

Latch holes have been located.  Next project is to install the metal latch catches.

Dec 13, 2021 Door frame

Category: Fuselage

Added "L" channel rubber to door frame. Glued on with CA, 20' of channel, couple inches at a time.

Add CA to a couple inches--then press and hold.

Try not to glue your fingers to the door frame.

Nov 30, 2021 More windshield work

Category: Fuselage

Drilled holes for the outer roof support tubes.

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Nov 24, 2021 Upper door frame to wing

Category: Fuselage

Upper door frame gets riveted to an aluminum bar to hold the frame in place. Front wing fairing can also be added, but that can wait for a later time when it is warmer in the hangar. There's some double sided tape that goes along the windshield and the A-post.

Blue upper door frame riveted to aluminum channel that fits up in the wing root.

No wing fairing--

Wing fairing installed...eventually.

Nov 07, 2021 Door and frame

Category: Fuselage

More door and door frame work.

Added a 3-1/4" hole in the upper window for a vent.

Making a relatively straight cut in the door frame to fit up tight to the wing root.

Nov 01, 2021 Door work

Category: Fuselage

Adding the plexi panels to the doors.

Some of the washers wouldn't fit over the rivets.  Opening them up with a dremel ibt.

Door with clear panels installed.

Oct 28, 2021 Door work

Category: Fuselage

Pre-fitting the door latch mechanism to see how it will all line up. Also trimming the windshield for a good fit.

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Oct 22, 2021 Door frames

Category: Fuselage

Working with a couple pretty flimsy pieces of fiberglass as door frames. Lots of fitting and cutting until finally you just have to drill a hole somewhere.

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Oct 19, 2021 Heat!

Category: Fuselage

Added a chunk of schedule 20 PVC to the cabin heat fan to keep it from blowing on the back of the instruments.

Under the dash.  Heat right between the knees.

Back to working on the door frames.

Oct 11, 2021 Door install, Part 1

Category: Fuselage

This looks like it could be a challenge---I've been warned that there is a lot of fitting, trimming, and re-fitting to this process.

For starters you have this flexible fiberglass frame that needs to match up to the structure.

What are the odds the door is going to fit

Hmmmm,....not bad for one afternoon's work.  Still need to drill holes and make it premanent.

Oct 08, 2021 Miscellaneous stuff

Category: Fuselage

Next big step will be mounting the door frames and doors. Need to do the final FINAL on the interior stuff first, like mounting the instrument panel, cleaning up the wiring nest, setting the throttle and choke cables, fixing some clearance issues, etc... Lots of progress; just not a lot of exciting new picturres.

Final bolt down of the windshield.

Clecos up the spine of the windshield, eventually to be riveted as soon as some help arrives.

Throttle linkage in center console.

A natural place to lay your weight...but don't do that!

Testing the labeling font size on paper.

Sep 29, 2021 Windshield install part 2

Category: Fuselage

The factory cut was mighty close to fitting perfect.

The front/center hole gets drilled first.

Work your way around the plexiglass sanding off what you don't want.  Belt sander worked great.

Drillng the trailing edge of the windshield  which will be riveted in place.

Line up the bottom of the windshield  on the rubber gasket and pop in a hole.

Top is covered with a perforated vinyl like the ads on bus windows.  Can't see in ....

....but you can see out pretty well.

Happy to see this installed.  Fit very well.

Sep 20, 2021 Windshield install part 1

Category: Fuselage

One quick picture from the day before connecting the aileron pushrod to the butterfly in the wing. Today it was on to the windshield install. Did a loose fit to see what kind of a project this is going to be.

Aileron butterfly with pushrod attached.

Temporary storage of the windshield.

String helps set the heights on the adjustable battens to support the top of the windsheild.

Windshield just laying on the plane.  This doesn't look like too bad of a job right now....

Sep 16, 2021 Rudder attachment

Category: Tail Feathers

Rudder is on and all the trim tab cables are connected.

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Sep 15, 2021 Day Off

Category: Workshop

Took a day off from building airplanes and went FLYING airplanes. Also, my grandkids made me an airplane out of perler beads to show me what the finished product should look like.

Waco bipe and RV4 at the Manitowoc flying field.

Inspiration.....

Sep 14, 2021 Trim tabs and control horns

Category: Tail Feathers

Rudder trim linkage attached. Elevator horn and linkage.

Thought I would try to tighten up the fuse sail one more time.

Rudder with horns and trim brackets...

...and linkage added.

Elevator control horn with cables attached.

Bottom exit of elevator control cable.

Sep 12, 2021 Rudder trim tab

Category: Tail Feathers

Attaching the trim tab to the rudder with 12 rivets.

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Sep 10, 2021 Nav Lights

Category: Lighting

Got the navigation lights wired up and tested out. Red on the left, Green on the right, right? Strobes are on the same unit.

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Sep 07, 2021 Attaching the elevator

Category: Tail Feathers

First added the trim tab to the elevator. The hinge pins slid right in no problem.

Trim tab attachment.

Slide in the hinge pins.

Starting to look like a complete airplane.

Sep 05, 2021 Stab flying wires

Category: Empennage

Attaching and tensioning the flying wires.

That recliner became an important part of the airplane build.

Had to make sure I didn't lose the nut inside the stab. Takes a steady hand and a comfy chair.

Tensioning the cables with the turnbuckles on the lower cables.

Done!

Sep 04, 2021 Jury struts and landing lights

Category: Wings

Added the jury struts to both wings. Trimmed and fit landing light lenses to the wingtips. Not planning on any night flying, so there are no lights behind those lenses. Can easily add them in the future--

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Sep 02, 2021 Installing the stab-

Category: Tail Feathers

We were warned that this was one of the worst jobs to accomplish of the build. So far they were right....

Stabilizer attachment bolts need to be installed through this little hole....

I planned ahead for dropped washers/nuts and installed this sling in the fuse to catch them.

Mark makes FINE adjustments as I try to slide the bolts in.

Giving the plane its first prostate exam...

The sling in action.  Saved us from losing 2 nuts and a washer.

All installed via the braille method.

Even got brother Jon's professional help.  3 Warning boys on one project is quite entertaining.

Aug 31, 2021 Pitot tube install

Category: Wings

Pitot tube installation out near the port wing tip. Tubing is run back through the rear strut along with the navigation light wiring for that side.

Pressure and static tubes along with lighting wires run down the rear strut.

Inside the left wing tip.

"Remove Before Flight"

Aug 27, 2021 Tensioning the sails

Category: Wings

Doing the "Tighten Up." Crank on the tensioning jigs to tighten the covering lengthwise, and pull on the laces for the short way.

Tensioning jigs in wing root.

Laces along the trailing edge.

Aug 24, 2021 Wing Tip mounting

Category: Wings

Fitting the wing tips. Also mounting the nav lights.

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Aug 21, 2021 Wing ends

Category: Wings

Installed one big fiberglass wing rib to give the wing tip something to mount to. Also something substantial for the fabric to stretch around.

Fiberglass end rib installed.

Pulling the fabric tight in the outer direction.

Aug 16, 2021 Both wings are ON

Category: Wings

Monday morning job complete after attaching the starboard wing.

Mark fights with the rear spar bolt.

Attaching the rear strut.

Starting to look like an airplane....

Aug 14, 2021 Port wing ON!

Category: Wings

Brother Mark and I attached the portside wing Friday morning. After fighting with that one for about 3 hours, we know the other side will go much easier now that we know the battles. Got sore shoulders holding up the wing while Mark did the bolts.

Wing attached.

Looking down the inside of the wing structure.  Leading and trailing edges only, no center spar.

How to move a wing by yourself using bubble wrap.

Aug 12, 2021 Aileron fences

Category: Wings

Mounting of the aileron fences. I forgot about these guys and just painted them yesterday. Picture looks like I'm drilling crooked holes....I'm not.

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Jul 31, 2021 Wing lacing

Category: Wings

Lacing up the wing sail all along the rear spar. Then slide in the pre-formed aluminum tubes to give the wing its shape. 10 pockets are there spaced across the top and bottom of the wing. Simple!

Lacing

More lacing

Sliding in the "ribs"

Jul 25, 2021 Wing covering

Category: Wings

Used the large shipping crate with a couple of interior doors screwed to the top to give me a table big enough to support the wings. Added mylar sheet to leading edge pocket in the fabric for rigidity. Used a box fan to blow powder in the pocket so mylar would slide easily.

Internal wing structure laying on the table.

Pre-sewn cover laying on the structure.

Sliding in the mylar.

Using the box fan to open up the pocket.

Jul 16, 2021 Moving Day!

Category: Workshop

Time to kick the little bird out of the home nest and into the hangar. Next steps are adding the tail and the wing. Many thanks for the help from Dan, Dale, and brother Mark....this was a much bigger project than I expected. It all made the trip just fine.

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No problem rolling it.

Towing up the hill.  It was easier to bring the plane to the trailer than the other way around.

Up the ramps and on to the trailer.

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Strapping it to the trailer.  The width of the wheels just made it on the trailer, so no bouncing!

Hangar at Wild Rose.

Wing structure fits in the back of my van.

Got to move those big crates out to the hangar, too.

Bushcat in its new home.

Jul 14, 2021 Engine pics

Category: Engine

Just a couple pictures of the engine now that it is all plumbed. Also added the air filters and safety wired.

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Jul 13, 2021 ELT connection

Category: Avionics

One last thing to do for the avionics is solder up the connector for the ELT.

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Jul 12, 2021 Fire up the panel!

Category: Avionics

This feels like we're making major progress now! Made all the necessary wiring connections and assembled the connectors. Temporarily added 5" extensions to the panel so I could see where the smoke came from when she fires up. Plugged everything in and applied power. It all works!

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Jun 26, 2021 Cabin heat install

Category: Engine

The hose with the stainless braid is the one sending hot coolant back to the cabin for heat. Quite the challenge trying to fit all this stuff in and not run into any conflicts.

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Jun 24, 2021 Cabin heat install

Category: Controls

Cabin heat is an option i thought might be a good idea for a Wisconsin plane. Since it is an adder option, you are kind of on your own to fit it in where you can. I bent up a bracket out of an old stainless microwave shell to mount the heaters where I think they will work best.

Bracket manufacture-

Had to make sure I had clearance for my big feet.  Heater radiator is just above my right shoe.

Jun 23, 2021 Technical Counselor visit

Category: Inspection

Tim from EAA came out and took a look at what was assembled so far. The picture says it all-

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Jun 20, 2021 Painting the panel

Category: Instrument Panel

More steps in the process--

Peeling off the protective sheet on the aluminum.

Pretty in Primer.

Beautiful in Black.

Jun 17, 2021 Cutting the panel

Category: Instrument Panel

Getting the panel cut for the instruments has been the biggest hurdle so far; trying to put together schedules with the right guy with the right tool. But it's finally done! I was able to provide a CAD drawing of what I wanted, but then it was up to Bryan G. and his magical router to cut it out of the aluminum blank provided with the kit.

Bryan in the driver's seat.

The router is doing its thing.  Cutting the panel from the back side.

I was trusted with running the vacuum.

The completed cutout.

At least I was able to provide the CAD file required to do the cuts.  Used LibreCAD...free download.

Jun 06, 2021 Wiring

Category: Avionics

Running the raw wires for termination later on.

Figuring out the schematic from the generic ones supplied.

Wires on the firewall for the regulator and capacitor.

Running the wires wild under the dash before connecting them to a plug.

Apr 25, 2021 Working on the electrical

Category: Avionics

Things have slowed down as far as visual progress right now. Gathering all the opinions I can for the avionics layout and mounting.

That's the Master Relay mounted up above my toes.

A wife with long arms comes in handy at times.  That black thing is the comm antenna.

Fuel pressure sensor installed.

Apr 13, 2021 Putting together the panel

Category: Instrument Panel

Taking some good advice and making a faux panel out of plywood first. Will try to avoid as many mistakes as possible! Still missing a couple breakers and switches, plus the spacing isn't correct yet, but this is a start.

Plywood cutout.  Got to start somewhere.

Pretty aluminum blank panel supplied.

Populated plywood panel installed, Version 1.

Taking this panel up for a test flight.

Apr 08, 2021 ELT install

Category: Avionics

ELT antenna mounted on aluminum angle off an existing bolt. Supplied ELT tray riveted to floor under the center console. ELT just snaps in.

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Mar 30, 2021 Plumbing the engine

Category: Engine

Time to hook up all the life's blood of the engine. Coolant system for the cylinder heads. Dry sump oil system. Fuel to make it go. Choke and throttle cables. Heat and pressure sensors.

Oil tank mounted on firewall.  Will be able to reach in from back of cowl to check oil level.

Mounted in lower cowl is the coolant radiator below, oil radiator above.

Regulator, capacitor, and starter relay mounted here.

Additional oil cooler mounted on top of the engine.  Orange lines are heat protected fuel lines.

Mar 23, 2021 Muffler Install

Category: Engine

Stainless Steel mufflers are so pretty. Assembled all pipe connections with Permatex Copper. Spring attachment tool was made from a white board hangar. Everything fit together perfectly.

Temporary connection with wire.

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Spring pulling tool...a must for this job!

Springs installed at all the joints.

Extension pipes installed...job done.

Mar 15, 2021 Cowl install

Category: Engine

These pictures really make me happy. Wasn't looking forward to fighting with the cowl to have it line up nicely. It's definitely a 2-man job, but brother Mark and I got it on there in a couple hours. At first it looks like there is no way it will match up to the fairing, but the more you mess with it, the better it fits. Attach the bottom DZUS, add the sides, then the 4 on top. Worked out perfect!

Adding the female DZUS fastener to the fairing.

That's not a headlight.  That's bubble wrap in the exhaust hole on the engine showing through.

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Mar 09, 2021 Cowl work

Category: Engine

Added DZUS fasteners to the cowl. Easy to do since the mounting holes for the fasteners were right in the mold.

Bottom half / Top half

All together for a preliminary look.

Mar 04, 2021 Engine mounting

Category: Engine

Installing the rubber mounts was a chore, but got them in there using plenty of lube and patience.

1/2 of the bottom rubber mount is in place.  Top is not connected yet.

All rubber mounts in and seated.

Mar 02, 2021 Carb mods

Category: Engine

Removed the carbs from the engine to press on the carb heat collar. Went and found some experience to do this task...

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Feb 27, 2021 Engine mods begin-

Category: Engine

Pictures of the carbs before removal. Engine mount goes on first---looks like you just bolt it on easily, but it was a bit of a battle with the rubber mounts and support washers and bolts. Doing some safety wiring on the oil outlet fitting on the engine belly.

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Feb 23, 2021 Engine Fetch

Category: Engine

Ran down to Galt Airport today to pick up the Rotax 912ULS. 4 of us loaded the pallet in my van at the airport, but once home I had to lean heavily on my helper. She was smiling the whole time....Really!

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It's all downhill from here.

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100 fire-breathing horsies in there.

Feb 09, 2021 Fuel Tank Install

Category: Fuel System

Tank fits in right behind the seats. Dual fuel pickups and filters, with fuel pump and gascolator below. The fuel filler is now on top of the fuse---on the previous version you needed to unzip the side panel to add fuel directly to the tank.

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Feb 06, 2021 Wing sub-assembly

Category: Wings

At kind of a stopping point with the fuse, so on to the wings. Re-arranged the building area to make room for the large crate, which made for a perfect building table for the wings. Not a lot of assembly required to get them to the covering stage. Going to move these structures out to the hangar for covering, rather than cover here and then try to move them without damage.

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Feb 03, 2021 First Flight!

Category: Fuselage

Finally get to start logging some hours flying this baby!

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Feb 02, 2021 On her feet!

Category: Landing Gear

Filled the brake lines with 5606 and packed the wheel bearings with 22. Finally off the saw horses and standing on her own.

I'm including this picture for those of you who just KNEW I never considered how I was going to get it OUT of the house. (Actually I had to pull the fuse out and turn it around for better access to the nose---engine is coming in a couple weeks)

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Jan 31, 2021 Seat backs and cushion, lumbar support

Category: Fuselage

Starting to look comfy in there. Held off on installing the seats as long as possible to allow for more working room in the cockpit. Waiting on bearing grease to complete the landing gear and get this thing off the saw horses.

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Jan 26, 2021 Tires, tubes, and brakes

Category: Fuselage

Mounted the tires/tubes on the split rims. Brakes will be installed once I get the bearings packed. Center console is being fitted.

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Jan 24, 2021 Cockpit structure

Category: Fuselage

Here's the tubing structure before most of it gets covered up by the floorboards and center console. Parking brake and fuel shutoff are on the floor.

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Jan 18, 2021 Permanent Firewall Install

Category: Firewall

Before riveting in the firewall, I took advantage of the big hole in the front of the plane to safety wire the throttle cables and hook up the brake hydraulics. Then it was on to pulling rivets to install the firewall. Reaching around the fairing to hold the backing washers for the rivets was a bit of a stretch, so I called in reinforcements. Yes, it cost me...

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Jan 11, 2021 Landing Gear Install

Category: Landing Gear

Pretty simple stuff--tap 2 holes and add bolts to keep the gear from shifting left/right, then secure gear to the fuse frame with 4 bolts.

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Jan 10, 2021 Spar assembly

Category: Wings

Getting things done during the football playoffs. Mounted all brackets to the wing leading (big ones) and trailing spars. Laid them back in their crate for later wing assembly. The Bears still suck.

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Jan 07, 2021 Firewall

Category: Fuselage

Adding heat resistant material to the fiberglass firewall. Glued on with contact cement.

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Jan 05, 2021 Firewall

Category: Firewall

Fiberglass firewall all cleco'd in. The entire front will eventually be covered with heat reflective material.

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Dec 27, 2020 Beginning to install the fun stuff-

Category: Controls

Cockpit is being assembled.

Flap handle above, control stick below

Seat belts strapped to the structure.

Battery is tucked up under the dash.  Compass on top.

Control stick mechanism.

Armrest install with throttle.  Checking clearances with the seat back in place.

Dec 24, 2020 Cockpit structure

Category: Fuselage

Now up to step 27! The entire airplane kit is all parsed out like this, with exploded views and text directions. Nice not having to scrounge parts---they are all right here in the gumball wrappers.

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Dec 22, 2020 Main Fairing install

Category: Fuselage

Big fiberglass chunk hooks over the engine mount and swings up to meet the bottom fuse structure. 4 bolts later you install the rudder/brake assembly. 2 more bolts and on to the next step-

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Dec 16, 2020 Fuse lacing

Category: Fuselage

Added fin and tailwheel so the fuse covering can now be done. Lots of lacing to do. Nothing difficult; just takes time.

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Dec 15, 2020 More Lacing

Category: Empennage

Just keep threading, one hole at a time. Feels, and is, time consuming, but compared to fabric, knots, tape, paint, etc...I'm sure this is quicker.

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Dec 07, 2020 Fin Lacing

Category: Empennage

There will be a lot of lacing/tightening to be done. Need to work on those wrinkles....

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Dec 03, 2020 Assembly goes quick!

Category: Fuselage

Just 2-1/2 days of assembly and it's time to start covering! Time to take a break from the fuse and start lacing up the fin.

Fuse structure

Laying on the sail

fin lacing

Dec 02, 2020 Day 2 of assembly

Category: Fuselage

Assembled through section 9, and it is already starting to take shape-

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Dec 01, 2020 First night of assembly

Category: Fuselage

The first 4 steps of assembly will get you this far in one night.

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Nov 29, 2020 Main Fairing, Cowl

Category: Paint / Decals

This paint dries to the touch in a couple hours. Main fairing is flat black for the top of the dash, also a black floor. The green will line up with the green on the cheeks. Cowl chunks got 2 coats of blue on the inside, then 3 coats of blue on the outside. Used Yellow Frog Tape for the lines. Lightly dragged x-acto knife along the tape/paint line before removing for a nice edge.

Main Fairing

Uppper Cowl

Lower Cowl

Main Fairing Done

Nov 25, 2020 Paint booth

Category: Paint / Decals

Might as well get all the painting out of the way. Paint from Automotive Supply in Appleton. I'm a rookie with acrylic enamel, but Mike there held my hand through the process.

Color match by eyeball from the rudder sail

Center console, spinner, radiator intake

Doors

Door frames

Wing tips

Nov 18, 2020 Delivery Day

Category: Crates

5 crates total, longest one is 15'. Total weight just over 1000#.

Loaded and ready to go from Galt Airport

Crate art from South Africa