Bushcat Build Log

Throttle and Choke Connection

Thu, 26 Feb 2026 09:38:09 GMT

The throttle cables outers had to be shortened, so this required pulling the outers off and removing the safety wiring on the throttle cables.
Initally when I tested the choke cable movement the chokes were not in synch across the 2 carbys. I found that one cable had popped out of the splitter.
I pushed it back in and was able to get equal movement.

Fuel Line Connection

Thu, 26 Feb 2026 09:33:54 GMT

Completed fuel line connection.
Had to add an extra length to the supply line to the fuel pump.
I made the mistake of cutting the fire proofing too short on a couple of hoses and corrected this afterwards.
I had to pull the cowling off again to drill a hole for the fuel pump vent line.
Whilst the cowling was off I secured the vent line.

I fitted the expansion bottle for the cooling system one evening during the week.
This took around half an hour.

Oil Cooling System

Thu, 26 Feb 2026 09:28:57 GMT

Complete fitting the oil cooling system

Oil Cooling System

Thu, 26 Feb 2026 09:21:54 GMT

Fitted the second oil cooler and fitted the rest of the hoses.
Did a trial fit of the top cowling to insure that the top oil cooler bracket was not sticking up too much to prevent fitting of the top cowling.
Had to pull the cowling off agian to attach the lower oil tank hose and drill a hole in the cowling for the oil tank breather.

Cooling System

Thu, 26 Feb 2026 09:17:30 GMT

More work adding the hoses for the carby heat jackets and trial fitting the expansion bottle.
Lots of hose clamps to secure. The larger ones barely fit so this makes it hard in places.

Cooling System

Thu, 26 Feb 2026 09:13:52 GMT

Continued with radiator and hose installation.
Had to do a trial fit, then take the cowling off, trim the hoses then put the cowling back on multiple times.

Cooling System

Thu, 26 Feb 2026 09:05:30 GMT

Fitted the radiator and bottom oil cooler after getting the lower cowling back after painting.
Also started cutting the remainder of the radiator hose sections and doing a trial fit.

Cowling installation

Tue, 27 Jan 2026 09:57:06 GMT

Had to repair one DZUS fastener location on the top of the cowling as it cracked when removing the rivet stem.
Fibreglass cloth and resin was applied.

3D printed brake line clips were installed and the radiator hoses and tubing assembly was started.

Cowling installation

Tue, 27 Jan 2026 09:54:31 GMT

Continue with fitting fairing DZUS fasteners.

Cowling installation

Tue, 27 Jan 2026 09:52:37 GMT

Started fitting main fairing DZUS fasteners.

Cowling assembly

Tue, 27 Jan 2026 09:50:28 GMT

Lot of work required to get a nice fit.
I had to install it, mark areas that needed trimming, uninstall, cut then refit multiple times.

Cowling assembly

Tue, 27 Jan 2026 09:47:55 GMT

Fitted Dzus fasteners to lower and upper cowl sections and did a trial fit on the fuselage.

Oil tank and rectifier installation

Tue, 27 Jan 2026 09:45:20 GMT

Completed installation of rectifier and starter solenoid.
Used a more heavy duty rivnut tool to instal the rivnuts.

Oil tank and rectifier installation

Tue, 27 Jan 2026 09:43:08 GMT

Finish tightening oil tank fitting and attach template for fitting rectifier.
Tried to install rivnuts however, the steel rivnuts were too hard to install with the rivnut tool that I had.

Wingtip Strobe Mount

Tue, 27 Jan 2026 09:38:50 GMT

Checked fitting of prototype 3D printed wingtip strobe mount.

It does not fit very well so I attempted to scan the wing tip without success.

The reflections wrecked the 3D model.
I will try scanning again the next time I am the hangar using some Aesub scanning spray.
I have printed another test mount and will try this also.

Wing Sail Installation

Tue, 27 Jan 2026 09:30:33 GMT

Complete conduit installation.
This did require slackening the sail cord to allow cable ties to be inserted around the leading edge tube inside the wing.

The sail cord then had to be retensioned.

Wing Sail Installation

Tue, 27 Jan 2026 09:27:27 GMT

Complete wing sail installation and install conduit with wiring for landing lights and strobes.

Wing Sail Installation

Tue, 27 Jan 2026 09:25:19 GMT

Install sail on left wing.

Oil tank and rectifier installation

Tue, 27 Jan 2026 09:22:07 GMT

Drilled firewall for fittings and installed oil tank.
Had to order an oil tank cap as none was supplied with the engine.

Exhaust Installation

Tue, 27 Jan 2026 09:01:49 GMT

Complete exhaust installation.