Bushcat Build Log

Instrument Panel - Main starter and power supply plug

Tue, 23 Jun 2026 11:08:01 GMT

Wired up Anderson PP45 plug with 10 AWG wire and crimped ring terminals.
These wires will be attached to the master and mag switches on the instrument panel.

Instrument Panel

Tue, 23 Jun 2026 11:13:55 GMT

Drill holes for switches and switch guards. Trial fit.
Drill holes for anti-rotation tabs using my 3D printed jig.
Deburr all holes.

Instrument Panel

Tue, 23 Jun 2026 11:00:39 GMT

Cut two more 3 1/8 holes for instruments in the instrument panel.
Ratchet handle made the job easier.
Also removed the cardboard insert so that the cutoff aluminium disk from the hole could be pushed out by putting a screwdriver through the hole in the hole cutting die.

Engine wiring

Tue, 23 Jun 2026 11:03:23 GMT

Finished wiring for magnetos. Fitted Soft Start modules. Applied Loctite on screws holding the Soft Start modules.

Instrument Panel

Tue, 23 Jun 2026 10:54:36 GMT

Marked and cutout hole for 3 1/8 inch instrument using hole cutter.
It took a lot of force to cut through. A ratchet handle on a socket would have made the job easier.

Wing sail installation - Strobe light conduit

Tue, 23 Jun 2026 10:48:12 GMT

Removed previously installed conduit as it was not flame retardant.
Installed new conduit and cable tied it to trailing edge tube for both wing halves.

Engine Wiring

Mon, 25 May 2026 11:58:53 GMT

Tony Bell inspected the firewall forward wiring and advised on how to improve the routing of the wires. He also suggested fitting a battery isolator in the starter circuit.
After his inspection, I fitted additional insulation for the starter solenoid and improved the wire routing. I also put the sensor and magneto wiring in silicon sleeves to provide extra protection.
Tefzel cable ties were used to secure the wiring. An Adel clamp will be added to secure the main loom to the firewall.

Gas Door Strut Upgrade

Mon, 25 May 2026 11:53:30 GMT

Install gas strut brackets in fuselage.

Engine Wiring

Mon, 11 May 2026 10:41:55 GMT

Added Deutsch plug to MGL EMS-2 sensor wiring.

Added Deutsch plug to the other wiring on the MGL EMS-2.

Finished installing EGT sensors and routing wiring.

Engine Wiring

Mon, 11 May 2026 10:21:43 GMT

Changed sensor plug from Molex to Deutsch plug.

Crimped terminal for oil temperature sensor.

Instructor Stick

Mon, 04 May 2026 11:31:59 GMT

Removed stick boot.
Insert instructor stick in boot and attach to stick with hose clamps.
Attach stick boot.

Engine Wiring

Mon, 04 May 2026 11:20:56 GMT

Continued with sensor wiring.
Tried using the Molex Minifit JR pins and plug for sensor wiring.
I am going to change to a Deustch connector as the molex pins are rotating in the molex plug and this could lead to problems with readings from the sensors.

Engine Wiring

Mon, 04 May 2026 10:56:30 GMT

More work on the engine wiring. Tidy up some of the wiring and put cable ties on the bundles.
Cut 18 AWG wires for engine sensors.
Put housings on Anderson PP45 connectors.

Door Assembly

Mon, 04 May 2026 11:38:59 GMT

Complete fitting of door hinges to doors and door frames.

Engine Wiring

Mon, 04 May 2026 11:41:43 GMT

Continued with engine wiring.

Door Assembly

Mon, 04 May 2026 11:44:09 GMT

Finish fitting windows in doors.

Engine Wiring

Mon, 04 May 2026 11:46:31 GMT

Continued with engine wiring.

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