Building the new Bushbaby SAFARI

[Oupa-G]

Tonight did some finishing touches on the cowling. Sat in front of the computer paid all the bills for the water jetting and laser cutting for the exhaust and other fittings.
That is a job that is part of building luckily very little is imported which makes it easier on the pocket. Every time I'm amazed with what I can get locally and the local talent and knowledge available. The engine mount is not yet painted I may want to add a tab or two once the exhaust is fitted when I do that I will weigh the whole installation. and I will give the results on the this site.

Cheers Oupa-G

[Oupa-G]

tonight I added some countersunk rivets to support the Epidermix epoxy on the metal backing for the Camloc fasteners. I am not sure how the Epidermix is going to stand up to heat and vibration so lets adopt belt and braces policy at the weight penalty of 26 stainless pop rivets. One can also see that it is now boot cowl time and that is also going to require some eyeball fitting ,

and then you still have the chance of cutting it twice and that it then is still to short

. I'm sure any serious home builder has come across this fenomina. Also busy cutting the baffles in cardboard to transfer the dimensions to the Cad program.

Cheers Oupa-G

[Carel]

My experience is that epidermix handles heat very well and vibration only a little less well. Cracking only start after quite a number of years.

3M has a product (epoxy resin) that handles heat extremely well and allow some movement within the body of the "glue" Widely used to repair (glue) broken rubber engine mountings (Rubber on rubber/rubber on steel). Will actually glue about all different types of materials. Also used in the joinery environment to glue timber joints in windows and doors. Provide a very strong bond and has excellent gap filling properties. Also water proof.

Not originally designed for the above purposes, but works 100%. I make entrance doors from railway sleepers in my spare time and some of the doors are only glued together. Some doors (250+kg) hang already for 10 years without cracks at the glued joints. Only draw back is the setting time of 4 hours and dry/use time of 8 hours.

Also very messy.

[Oupa-G]

Dear Carel

Thank you for the feed back I would be glad if you can send me the name and # of the product. The carbon fiber tube on the gear would have done better with the glue described because they also need that slight movement ability. Send us the detail on this site then other people can benefit.

Cheers Oupa-G

[Boet]

Clocked back in at 10.45 this morning. Dog tired. ANS then the rest of the day was very busy too. No rest for da boss. I am going to bed RIGHT now. I am going to keel over and flatline....... ZZZZZZZZZZZZZZZZZZZZzzzzzzzzzzzzzz

[Oupa-G]

Had a wonderful visit from the CAA in my workshop I was proud to show them the work we have been doing and the whole evening was seriously aviation. I see a bright future for our beloved sport. I the past week I have been a bit quiet but I copied the Baffles and the carton copies will now be digitized and then make DXF files of them so that we can either Laser cut them or Waterjet them. It is so important to control the airflow around the engine.

Cheers Oupa-G

[Oupa-G]

Also received the oil cooler and the workmanship is superb and the position behind the baffles is nice it will get its own little cowling and duct . Watch this space and we will send the pics.I'm working hard because I do not want to miss the deadline of end of April. By that time the wings will have been stress tested and the Safari will be a properly stressed aircraft. Enclosed the pics of the Oil cooler I have a place for a temp probe on the inlet and the outlet. Also the internal flow is three way preventing shunting inside the cooler. The cooler has plenty of capacity because I do not want overheating in the hot and high climates. We know that at 10,000 we loose 20% of efficiency just because the cubic meter of air has 20% less molecules of air to absorb heat. So at sea level there is to much capacity but the thermostat will take care of that. Happy viewing

Cheers Oupa-G

[Oupa-G]

Now that the oil cooler has its fixed place the other parts find their rightful places. The MGL box into which all the engine signals are fed is mounted on the left hand side then it is closest to the Odyssy and the transmission wires go through the firwall I use the stainless fitting that have a rubber gland and a perfect seal . One can get these fittings in different sizes and makes the wires through the firewall very neat. Boet arrived from Loeriesfontein with the wings of the Bosvark so all components are here so there is no excuse not finishing the project. Just some quick photo's

Cheers Oupa-G

[Oupa-G]

Had some serious shopping sessions for fittings for the oil pipes and the air ducting have had no chance for photo's. Had my hard disc go down on my main computor and that is setting my flow back a little but I will survive. Next week I'm out of town and then Boet must take over with the news reporting. But I promise to post a whole bunch of photo's before I leave.

Cheers Oupa-G

[AndyCAP]

Double post

[AndyCAP]

Exciting stuff!

Good to hear you had a positive experience with the CAA.

My mate Conrad FINALLY received his ATF for his topless aquilla (wing built by Jenja) after almost a year of cat and mouse games and seemingly neverending changing requirements from the CAA

But lets not be negative - at least there is progress and although slow - in the right direction! Well done CAA!

Good luck with the last 10% (which usually takes 90% of the time )

Cant wait for those first reports on flying Bosvark

all the best
AC

[Oupa-G]

Thanks Andy Cap,
I'm working hard to not let the last 10% take 90% of the time Did some more bracket measurement on the oil cooler . Today received back all the Laser pieces so now I can give the whole project a serious push forward . The exhaust is always difficult and sooooo'h important most under cowling fires come from the exhaust system and fuel and oil lines this is the only place where apartheid is still important keeping these lines and the exhaust far apart. I our design a lot of attention has been given to this topic. The first two photo's are the oil cooler bottom bracket and the bracket that will house the two fuel pumps and filters etc.

Cheers Oupa-G

[Oupa-G]

I see there are now more then 18000 hits thanks guys and girls for watching I hope I'm not boring the readers. I try to keep it as factual as possible . On the design of the exhaust of course a lot of reading was done and I came to the final conclusion that in the end you have to build the exhaust and test it. Luckily on the Vliegvark we kept the standard BMW exhaust as close to original. So we can fit the new exhaust and just swap and we will know the difference. With this exhaust the two cyl exhaust come in from the side and then the exhaust pipe self comes out either side. We hope for a nice quiet silencer as not making noise is our main aim. I f it costs a few horses I will have to live with it. Silence is golden ( and then they say duct tape is silver )I have taken photo's of the various parts you will see we use the flexible coupling we have used these couplings in both Trikes without any problems they give a great flexibility which prevents cracking.Enjoy the photo's

Cheers Oupa-G

[Oupa-G]

The whole internal pipe setup is then covered with 3 plates this was done to facilitate the welding process. You have to think clearly what you weld first and last no tracing back unless you want to grind the exhaust open again. We are making 3 exhausts One for Bosvark then another for Safari #2 and then the test exhaust on the Trike . The testing and the comparison is paramount. The shape was made triangular it is supposed to help with the bouncing of the sound wave in the box
Our ears and the testing equipment will tell the story. By bringing the headers straight into the box we save weight and simplicity is King. I'm privileged to have Vliegvark with his 3D brain to create the DXF files this makes life so much easier and then he can do some mean welding as well.

Enjoy the photo's


Cheers Oupa-G

[Boet]

That ekzos system lyk baie mooi!! I can hardly wait. Oupa obviously have beeg plans for this aerie. Safari no2 is progressing by leaps and bounds. Everything is now painted white. Colour trim to go on early next week. Kust spoken to Oupa. Wiil be nice to see him here on Sunday! We are very busy indeed!!