Page 1 of 2 12 LastLast
Results 1 to 40 of 75

Thread: Bushwacker 2.0 a.k.a. Cub Killer

  1. #1
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like

    Bushwacker 2.0 a.k.a. Cub Killer

    Bushwacker rebuild is finally complete, still working the bugs out so not completely satisfied yet. Here are some of the details of the rebuild:
    Extended the 33'8 wing to 36' (added 12" to each spar and used the Dakota wing tips)
    Shortened the flaps from 120" to 114"
    Extended the ailerons from 60" to 77" (best flying Experimental Maule ever for roll control)
    Went from Lycoming O-360 (180hp) to Lycoming IO-360 (200hp)
    Went from 90" fixed pitch to 84" constant speed propeller
    Added the tip tanks back in for a total of 67 gallons of fuel from the original 44 gallons.
    Changed the yoke side by side seating to center line seating with stick for pilot and cub style heal brakes and rudder peddles, moved the rear sling seat forward 6"
    Changed the angle of incidence of wing attach fittings from 1 11/16" to 3 1/8" (made horizontal ground adjustable to get the angle correct after initial testing)
    Made cub style cowling and custom dynafocal engine mount shortened and lowered
    Weight before rebuild 1325 with empty CG at 12.6 weight after rebuild 1359 with empty CG at 13.0 (gross weight of 2500)
    Simplified instrument panel and lowered top by around 3"
    Made the extended baggage flat with the rest of the baggage area so there is around 7 feet of flat floor from the back of the cub style seat to the back of the baggage.

    I only have a few hours in it but based on what I have seen so far it looks like it will cruise around 117 mph at 2350 rpm at sea level (not sure how much power I am putting to it because my Dynon is out of it for repair) but it is not firewalled at that speed. I would guess I am probably at 25" of manifold pressure.
    it will land at around 35 mph GPS and the visibility over the nose is better then my cub.

    Click image for larger version. 

Name:	bushwacker2_jpg.jpg 
Views:	591 
Size:	53.0 KB 
ID:	41145
    Thanks AkPA/18, multimauler thanked for this post

  2. #2

    Join Date
    Nov 2014
    Posts
    8
    Post Thanks / Like
    Very nice would like to see more pictures of it
    thanks Steve

  3. #3
    PerryB's Avatar
    Join Date
    Aug 2007
    Location
    Northern Calif.
    Posts
    1,762
    Post Thanks / Like
    So that's the angle valve 360 with the flat valve covers?
    Considering the wing extension and the general size of the machine, the empty weight is pretty impressive, and the slight shift aft can only make it a touch lighter on the controls. I want a ride. No, actually I want to FLY it !!
    After Monday and Tuesday, even the calendar says WTF !

  4. #4
    flyrite's Avatar
    Join Date
    Mar 2013
    Location
    Lyons,GA
    Posts
    381
    Post Thanks / Like
    One of the few planes I’ve considered building my own version of. Have watched you put the original thru its paces more hours than I can count. Would love to see some video of the thing flying some STOL .
    Congrats on getting it back up.
    Thanks pfm thanked for this post

  5. #5
    tedwaltman1's Avatar
    Join Date
    Jul 2011
    Location
    Denver, CO
    Posts
    364
    Post Thanks / Like
    Thank you for the specs. I’m curious re your prop. How did you select the length? Who’s prop—Hartzell, Whirl Wind, ?

    Again, thank you!

  6. #6
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    Click image for larger version. 

Name:	20180216_152710.jpg 
Views:	417 
Size:	237.2 KB 
ID:	41153Click image for larger version. 

Name:	20161206_143456.jpg 
Views:	388 
Size:	207.0 KB 
ID:	41147Click image for larger version. 

Name:	20161128_202544.jpg 
Views:	405 
Size:	203.8 KB 
ID:	41149Click image for larger version. 

Name:	20180216_152624.jpg 
Views:	418 
Size:	162.3 KB 
ID:	41151Click image for larger version. 

Name:	20181224_145923.jpg 
Views:	441 
Size:	143.9 KB 
ID:	41152

  7. #7
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    So yes it is an angle valve IO-360 Lycoming and Hartzell compact propeller. Tom, Laurie and Greg at Western Propeller put it together with my type of flying in mind. I told them I wanted it to turn up to at least 2700 rpm on takeoff which it does I am still playing a little bit with that and until I get the Dynon back I probably won't have it set where I want. The climb out feels really strong with this prop. I have not heard from the ground of course but I guess it is pretty loud which I did not particularly want.
    Thanks tedwaltman1 thanked for this post
    Likes mike mcs repair, Hardtailjohn liked this post

  8. #8
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    I went with a Garmin G-5 (very cool, love it), Dynon EMS-D10 (so far I am regretting that) and a Garmin 660 aera, MGL V6 com.

    Here is the down side with the Dynon, back light quits while I am changing sensor settings on the ground before first flight. I send it back overnight and they don't check it in for 3 days. They say they normally turn repairs around in 10 business days. Well it looks like they are going to take at least 10 business days to do that so I am without most instruments for engine. I am using a oil pressure gauge that I mounted in place of the Dynon and a hand held tach that I shine through the windscreen. I am not sure if I will ever do a all in one engine monitor again. In fact I am pretty sure I won't.

  9. #9
    mvivion's Avatar
    Join Date
    Jun 2003
    Location
    Bozeman,MT
    Posts
    10,345
    Post Thanks / Like
    I'm impressed that you were able to make all those changes from the original and still keep the weight down. Awesome!

    MTV

  10. #10
    PerryB's Avatar
    Join Date
    Aug 2007
    Location
    Northern Calif.
    Posts
    1,762
    Post Thanks / Like
    If it's loud, it must be the exhaust system. An 84" prop turning 2700 RPM has a tip speed of 675 MPH. The speed of sound is something like 760 MPH @ sea level/standard day.
    I have the FAD Hotrod on my 320 so we're kinda in the same boat as noise goes.
    After Monday and Tuesday, even the calendar says WTF !

  11. #11

    Join Date
    Nov 2007
    Posts
    92
    Post Thanks / Like
    The new plane looks great. I can’t wait to see it in action. Great color choice as well!

    joe

  12. #12
    Barnstormer's Avatar
    Join Date
    Sep 2013
    Location
    Sterling, Alaska
    Posts
    718
    Post Thanks / Like
    Looks great! Congrats.


    Sent from my iPhone using Tapatalk Pro
    Phil Whittemore

  13. #13

    Join Date
    Dec 2004
    Location
    Inkom, Idaho
    Posts
    1,266
    Post Thanks / Like
    Looks like plenty of elbow room! That center seat is so hardcore......, that says more them most of your other mods as to how you plan to use it. For a tandem plane pilot, I'd feel lost in that thing, like I had shrunk.
    Likes mike mcs repair, Farmboy liked this post

  14. #14
    aktango58's Avatar
    Join Date
    Aug 2004
    Location
    18AA
    Posts
    9,045
    Post Thanks / Like
    Very nice for someone just wanting to go for a flight alone and land where others can not!! The center front seat is interesting, though the stick would be a great deal better than yoke.

    Coming north this spring? would love to check it out in person.
    I don't know where you've been me lad, but I see you won first Prize!

  15. #15
    Southern Aero's Avatar
    Join Date
    Jan 2008
    Location
    kcco/1ga2
    Posts
    166
    Post Thanks / Like
    That's the 3 blade Hartzell isn't it?
    ......... It doesn't cost any more to go first class! You just can't stay as long.

  16. #16
    hottshot's Avatar
    Join Date
    Jun 2002
    Location
    Joseph ,Or
    Posts
    1,069
    Post Thanks / Like
    looks great Greg!!

  17. #17
    Olibuilt's Avatar
    Join Date
    Nov 2009
    Location
    Montreal, Canada
    Posts
    806
    Post Thanks / Like
    That is some serious cargo space. Center seat is something we don't see every day.
    Glad your custom propeller makes your engine scream.

    We need some video please!

  18. #18
    DJ's Avatar
    Join Date
    Jan 2009
    Location
    Bolivia
    Posts
    180
    Post Thanks / Like
    Awesome. Agree on the G5.

    Sent from my SAMSUNG-SM-G900A using SuperCub.Org mobile app
    The heavens declare the glory of God; the skies proclaim the work of His hands. Psalms 19:1

  19. #19

    Join Date
    Nov 2007
    Posts
    92
    Post Thanks / Like
    The new plane looks great. I can’t wait to see it in action. Great color choice as well!

    A couple of questions...

    So it is a Cub wing? Stock or Dakota, Javron, etc?

    Is this the original Bushwhacker fuselage(M5) reworked and modified? Or did you build a whole new fuselage from scratch?

    Lastly, what covering system did you use?

    Joe
    Thanks FdxLou thanked for this post

  20. #20
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    They are the wings that were on Bushwacker before the accident, started life as the biggest wing Maule ever built 33'8". I needed to reskin both of them after the accident and since I was already in them and always wanted just a little more length I decided to do a spar splice and add a foot. I also never liked how the Maule wing tin canned so easy so I went with .025 skin on both sides vs .020 on the top and .025 on the bottom like Maule does it. I wanted it to be more sporty in all kinds of conditions so this allowed me almost 12" more aileron, I did not feel that was good enough so I shortened the double slotted flaps by another 6". This wing originally had 126" flaps and 54" ailerons which really sucked in windy conditions. I had already shortened them by 6" when I went to the double slotted flaps. With these changes it really handles like I have always wanted for roll control.

    I used stits with aerothane for the covering and paint.

    It is a two blade Hartzell, experimental propeller that was built with something like 8.5 degrees and 38 degrees at the pitch stops. Not really sure how that compares to my fixed pitch 90" which was pitched at 33 but it seems to work pretty well right off the bat. It is amazing feeling the 200hp at 2700 rpm with the constant speed vs the 180 hp at 2450 with the fixed pitch. In reality the 2450 was probably around 160 hp with the 10.5 to 1 pistons.

    The fuselage was bare tubing nothing added except the gear attach, engine attach, strut attach. It had no pulleys, no sheet metal and no wing attach. Made it easy to make it the way I wanted but was a lot of work. The old fuselage was not used.

  21. #21
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    It might be a few weeks but I will get some video and post it on Youtube.

  22. #22
    hotrod180's Avatar
    Join Date
    May 2008
    Location
    Port Townsend, WA
    Posts
    2,518
    Post Thanks / Like
    Quote Originally Posted by PerryB View Post
    If it's loud, it must be the exhaust system. An 84" prop turning 2700 RPM has a tip speed of 675 MPH. The speed of sound is something like 760 MPH @ sea level/standard day......
    84" at 2700 on a standard 59 degree day = .88 mach.
    That's the bottom end of the .88-.92 "sweet spot" according to Pponk's tip speed calculator.
    As far as loud goes, when I pull back the MP on my C180 after takeoff but leave the prop alone,
    it gets a lot quieter inside the airplane.
    Is that just less exhaust noise, or doe the fact that there's a lot less oomph behind the 2600 rpm make a difference too?
    Cessna Skywagon-- accept no substitute!
    Thanks Jonnyo thanked for this post
    Likes barrow pilot liked this post

  23. #23
    PerryB's Avatar
    Join Date
    Aug 2007
    Location
    Northern Calif.
    Posts
    1,762
    Post Thanks / Like
    I don't think propeller AOA would have much -if any- effect unless maybe you were right at the edge of sonic, and then that's just speculation / imagination on my part.
    Last edited by PerryB; 01-28-2019 at 09:31 PM.
    After Monday and Tuesday, even the calendar says WTF !

  24. #24
    flyrite's Avatar
    Join Date
    Mar 2013
    Location
    Lyons,GA
    Posts
    381
    Post Thanks / Like
    Coming from someone who likes turning the molecule from the ground to as much noise as possible . It’s normally the high RPM with flat pitch that sends the neighbors 15 miles away the message that your up!

  25. #25

    Join Date
    May 2009
    Posts
    2
    Post Thanks / Like
    Way to go Greg! It looks like you put a lot of thought into build. I like that you did away with the lower half of the instrument panel. What did you make your doors out of? What did you do for an interior? What about starter, alternator, and battery? I would love to hear how it flys with two guys in the back seat and a couple of back packs.
    Isaac

  26. #26
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    Yeah those two bars, one on each side of instrument panel make great handles for pulling yourself up and in when on 35" ABW. I used the stock door frames modified for angle of incidence change with no center bar and covered them in .060 hardcoated polycarbonate, super lightweight. I used the camper type shock to hold them open they are hinged from the top and the latch is in the bottom (just a single pin that drops in the jam). Interior is .020 aluminum and powdercoated with honeycomb composite floor boards. I used Oratex above the waterline to keep from poking the outer fabric with objects inside. BNC starter, BNC 20 amp accessory mount alternator, PC-680 battery. I machined the magnesium sump for a forward facing fuel servo, keeps it real simple and ram air, I made the airbox attach to the bracket air filter (very short) with a door for alternate air. Still testing with it light, will load it up very shortly and see how well it does.
    Thanks isaac thanked for this post
    Likes CamTom12, Hardtailjohn liked this post

  27. #27
    FdxLou's Avatar
    Join Date
    Apr 2004
    Location
    Atlanta Ga. 6ga0 Stoney Point Airfield
    Posts
    1,763
    Post Thanks / Like
    Greg
    Try an EarthX battery and save another 8-10 lbs. Cranks faster than any Odyssey!

    Lou
    Likes flyrite, kestrel liked this post

  28. #28
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    I would like to use earth x but I am worried about having it inside the cockpit. I currently have it mounted on the firewall cockpit side. I was reading on EarthX web site they don't recommend having it inside.
    Likes mike mcs repair liked this post

  29. #29
    CamTom12's Avatar
    Join Date
    Jul 2015
    Location
    Huntsville, AL
    Posts
    604
    Post Thanks / Like
    Quote Originally Posted by Mauleguy View Post
    I would like to use earth x but I am worried about having it inside the cockpit. I currently have it mounted on the firewall cockpit side. I was reading on EarthX web site they don't recommend having it inside.
    Mine’s mounted on the firewall, cabin side. Been there for a couple of years, no issues.

  30. #30
    brown bear's Avatar
    Join Date
    Feb 2004
    Location
    emporia ks
    Posts
    541
    Post Thanks / Like
    Mauleguy
    Where did you get your .060 hardcoated polycarbonate ? I have not been able to find the Hardcoat in .060.
    Thanks Doug

  31. #31
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    [COLOR=rgba(0, 0, 0, 0.87)]Laird Plastics Inc.
    [/COLOR]Phone: (503) 233-4861
    Phone: (503) 233-4861
    Thanks brown bear, Nefj40, Jonnyo thanked for this post
    Likes mike mcs repair liked this post

  32. #32
    FdxLou's Avatar
    Join Date
    Apr 2004
    Location
    Atlanta Ga. 6ga0 Stoney Point Airfield
    Posts
    1,763
    Post Thanks / Like
    Quote Originally Posted by Mauleguy View Post
    I would like to use earth x but I am worried about having it inside the cockpit. I currently have it mounted on the firewall cockpit side. I was reading on EarthX web site they don't recommend having it inside.
    Greg
    EarthX has a fully vented battery (ETX900VNT) for use inside the cabin.
    Lou

    1
    Likes kestrel liked this post

  33. #33

    Join Date
    Nov 2007
    Posts
    92
    Post Thanks / Like
    Quote Originally Posted by Mauleguy View Post
    It might be a few weeks but I will get some video and post it on Youtube.
    Greg, that would be great. I would really like to see some more photos of your finished interior as well. I’m really excited to see this plane fly—I think the concept and changes are great.

    Joe

  34. #34

    Join Date
    Oct 2013
    Location
    SEA/MSP
    Posts
    26
    Post Thanks / Like
    Congrats Greg! Another impressive build. Can't wait to see it perform as you get it all dialed in. As conscientious as you are about weight, what made you decide on the aluminum blade hartzell over some of the carbon/wood composite props? I noticed Bushwheel Bill's 540 powered pumpkin maule had a few MTs on it before going back to aluminum. I figured you guys had a reason for choosing what you did.

  35. #35
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    It is mostly a money thing for me, I can buy 4 or more of the Hartzell propellers for what it would cost me for 1 MT. Bushwacker has plenty of weight in the tail so lighting the propeller is not going to be as much of a pay off as it is on a cub. I still run a 1p235 on my Super Cub even though pretty much everyone else that is experimental runs a composite. I like the fact that I could straighten or cut off what is left of a metal prop and still get somewhere. Not sure with a constant speed that is an argument in favor of a metal but for a fixed pitch it is.

    It comes down to dollars though, if MT wanted me to test something and it only cost me 3500 like my prop did I would be all in!

  36. #36
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    Click image for larger version. 

Name:	20190202_114051.jpg 
Views:	289 
Size:	194.8 KB 
ID:	41258Click image for larger version. 

Name:	20190202_154830.jpg 
Views:	1851 
Size:	111.1 KB 
ID:	41259Click image for larger version. 

Name:	20190202_154813.jpg 
Views:	234 
Size:	71.7 KB 
ID:	41260Click image for larger version. 

Name:	20190202_155010.jpg 
Views:	236 
Size:	141.9 KB 
ID:	41261Click image for larger version. 

Name:	20190202_154919.jpg 
Views:	269 
Size:	47.8 KB 
ID:	41262Click image for larger version. 

Name:	20190202_154905.jpg 
Views:	243 
Size:	152.8 KB 
ID:	41263
    Thanks Steve Pierce, Jonnyo, Farmboy thanked for this post

  37. #37
    skywagon8a's Avatar
    Join Date
    Mar 2008
    Location
    SE Mass
    Posts
    9,060
    Post Thanks / Like
    Mauleguy, Is there a back seat which plugs into the baggage door when it is closed? Your plane looks great.
    N1PA
    Likes mike mcs repair liked this post

  38. #38
    Bill Rusk's Avatar
    Join Date
    Jan 2003
    Location
    Spokane Felts Field, WA/Poplar Grove, (Chicago) IL
    Posts
    5,172
    Post Thanks / Like
    Greg

    Very very well done. I look forward to seeing it in person sometime. Best regards

    Bill
    Very Blessed.

  39. #39
    Mauleguy's Avatar
    Join Date
    Aug 2002
    Posts
    640
    Post Thanks / Like
    Quote Originally Posted by skywagon8a View Post
    Mauleguy, Is there a back seat which plugs into the baggage door when it is closed? Your plane looks great.
    Yes, it has a rear seat like the Maule for two passengers. I moved it forward around 7" from the stock position of a Maule. The passengers would get in the front doors now from either side and there legs when seated would go up to the main structure cross bar. It actually gives them more leg room then a stock Maule. I have not had it in since I did the fuselage build up but the wife will get a ride soon. I have about 7 hours on it now so still getting use to it but for the most part it feels like a Super Cub. The visibility is much better than my Super Cub both landing and taxing on the ground.

  40. #40
    Southern Aero's Avatar
    Join Date
    Jan 2008
    Location
    kcco/1ga2
    Posts
    166
    Post Thanks / Like
    Quote Originally Posted by Mauleguy View Post
    Click image for larger version. 

Name:	20190202_114051.jpg 
Views:	289 
Size:	194.8 KB 
ID:	41258Click image for larger version. 

Name:	20190202_154830.jpg 
Views:	1851 
Size:	111.1 KB 
ID:	41259Click image for larger version. 

Name:	20190202_154813.jpg 
Views:	234 
Size:	71.7 KB 
ID:	41260Click image for larger version. 

Name:	20190202_155010.jpg 
Views:	236 
Size:	141.9 KB 
ID:	41261Click image for larger version. 

Name:	20190202_154919.jpg 
Views:	269 
Size:	47.8 KB 
ID:	41262Click image for larger version. 

Name:	20190202_154905.jpg 
Views:	243 
Size:	152.8 KB 
ID:	41263
    Very nice ideas and workmanship! I wish you were closer, I'd con you into helping me finish mine! Maybe I'll get to see it if I make it north next year.
    ......... It doesn't cost any more to go first class! You just can't stay as long.

Similar Threads

  1. New Garmin GDL 39 - XM WX killer?
    By Bugs66 in forum Cafe Supercub
    Replies: 42
    Last Post: 04-01-2014, 05:19 PM
  2. Replies: 11
    Last Post: 10-13-2013, 12:56 PM
  3. Searching and Tagging is KILLER!
    By SJ in forum Cafe Supercub
    Replies: 5
    Last Post: 12-05-2010, 10:54 AM
  4. Bushwacker Air Parts?
    By supercub in forum Cafe Supercub
    Replies: 2
    Last Post: 06-03-2009, 08:27 AM

Bookmarks

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •