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New kid on the block - Smith Cub

Buzzcola777

MEMBER
Montreal, Canada
INDEX
PostTitle
#10Aircraft Arrival
#14Project Starts
#22Interior cardboard templates
#24Upper Cabin Templates
#36Aluminum Panels - Lower Baggage Section
#42Aluminum Panels - Upper Baggage Section - Part 1
#43Aluminum Panels – Upper Baggage Section – Part 2
#50Aluminum Panels - Cabin Area - Side
#51Battery / Storage Box
#57DARN! Modifying Top Panel - Cabin Area
#58Cabin - Front Panels & Floorboards
#67Cabin - Wing Root Fairings
#68More about Floorboards...
#69Overhead Trim
#70Firewall
#75Boot Cowl Assembly - Part 1
#80Boot Cowl Assembly - Part 2
#101Carpeting
#104Rudder Pedals Installation- Part 1
#105Fuel System - Gascolator Bracket
#121Fuel System - Fuel Lines - Part 1
#135Rudder Pedals Installation - Part 2
#136Fuel System - Fuel Lines - Part 2
#156Fuel System - Fuel Selector Valve Cover
#158Heating System - Part 1
#171Heating System - Part 2
#177Heating System - Part 3
#178Brake Pedals...
#182Electrical / Avionic and the like...Part 1
#198Cutting out the Instrument Panel
#204Electrical / Avionic and the like...Part 2
#220Electrical / Avionic and the like...Part 3
#233Electrical / Avionic and the like...Part 4
#251Electrical / Avionic and the like...Part 5
#252Electrical / Avionic and the like...Part 6
#257Electrical / Avionic and the like...Part 7
#258Throttle Quadrant - Part 1
#261Throttle Quadrant - Part 2
#262Wheels and Brakes
#265Braided Brake Lines Installation
#271WING - Fuel Tanks
#275WING - Fuel Tanks - Drain Covers
#276WING - Flap Fairing
#277WING - Wingtip
#278WING - Miscellaneous
#281PRE-COVER INSPECTION
#287FABRIC - Part 1
#297FABRIC - Part 2
#298FABRIC - Part 3
#305Antennas - ELT & COM
#306Under Floor Metal Belly
#307Floats - Mounts & Brackets
#313Fuselage - Grommets & Inspection Windows
#320Plexiglass - Doors & Windows
#325FABRIC - Part 4 - Fuselage
#326Seats & Seat Belts
#327Upholstery
#328Wheel - Hub Cap Cover
#329Baggage Doors
#335Fuel System - Fuel Probe & Gauge
#339Windshield & Skylight
#345RECAP

Folks,
Retirement at last!! Happy not because I did not like to fly, Nooooo…Happy because I’m finally starting a long-time dream about building an airplane…Not any airplane but a PA-18 Supercub. A bit about myself, 45 years as a pilot including 30 years in the Canadian Forces, experimenting all kinds of toys Jets & Helicopters (even a stint on F-104 Starfighter – that tells you a little bit about my age!) and lately 8 years in UAE (Dubai & Abu Dhabi) flying offshore & VVIP on AW139.

Now, the real stuff! This thread will be about the building of a Supercub kit provided by Nick Smith of BBI Aviation (http://bbiaviation.com) located in Ontario – Canada. So to start with, I pretty well did like everybody else, which is reading everything referring to the Supercub then I ordered the Northland CD, studied it and went down to Nick’s place to talk aviation. Nick & his son (Nick Jr) are simply gentlemen! Nothing is complicated with the Smiths and they’ll add any modifications to your project with no additional charges!! I was hooked and order a kit!

Upon my return, (I live on the South shore of Montreal), I built a workshop in my garage and bought a bunch of tools just to look like someone who knew what he was doing. Now, this cub will have a 0-360 pulling the beast with pretty well all mods available today for this type of aircraft. I’m planning to cover it with the Stewart System due to the fact that I’ll do it at home and want to stay married for a couple more years.

I am a first time builder...so I will post a bunch of photos of my project and rely on you guys to point me in the right direction if you see something that just does not make any sense or simply suggesting a better / easier way to do things! So, here we go…

Dan

Visit Smith Cub 011.jpg
Visiting BBI Aviation with Nick Smith in his shop (fuselage section)

Visit Smith Cub 043.jpg
Wing Workshop

NA001 005.jpg
Now, let's make an opening for the new workshop at home

NA005 001.jpg
Wife said: OMG!!

NA012 004.jpg
Getting there...

Photos 020.jpg
Wife said: OK carry on!

Photos 057.jpg
Garage ready!

Z105a.jpg Z111.jpg Z121.jpg
Worshop ready!! Fumes & dust meet your friend!

More to follow...
Dan
 

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You seal the floor with 100% polyaspartic (colour of your choice) then you add the flakes and finally you seal it with 100% clear polyaspertic...Will resist pretty well to all kind of spills.
 
Dan, I sure like your work table. What did you coat the plywood with?

Kurt
 
Beautiful workshop. Is that an Aeronca fuselage? I spent a lot of time in the UAE and most of the 'stan's. Always glad to get back home from there. Wish I would've installed a dust collection system years ago (cough cough)
 
I’m envious of all of you with mechanical talent. My IA says the only hand tool I’m allowed to use is my cell phone. Beautiful shop, I’m sure the airplane will be the same. As they say, a good landing begins with a good approach.
 
Beautiful shop. Starting out well organized, which is a major help. Good luck with the build! Keep us posted. I built an SQ-2--of course Smith Cubs are my ancestor :lol:
 
Good eye! It is actually a Citabria 7GCBC that I've flown for couple years. I removed the fabric and put in storage for the time being.
 
Aircraft arrival

Here we are! The cub has arrived! Delivered by Nick himself!! He is around 78 years old and travel across Canada & USA by himself to deliver his babies...Amazing! So, photos of the arrival + a little description of what is included in the kit. In order to get further details , go to Nick's web site (http://bbiaviation.com) - Kit for sale - PA18.

02.jpg 082.jpg 098.jpg

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Very nice project! Had the chance to meat Nick Smith, he is a real gentleman and does awesome work.

I'm a little north of Montreal in St-Eustache, and my exp Cub is in my backyard, if it can help.
 
Very nice project! Had the chance to meat Nick Smith, he is a real gentleman and does awesome work.

I'm a little north of Montreal in St-Eustache, and my exp Cub is in my backyard, if it can help.

Tiguidou Oli, I'm sure I'll need all the help I can get!!
 
Let's start this project!

Now that I brought the fuselage to my house, it is time to start building! But, hey, where do I start??? The kit comes with no documentations whatsoever…Panic!! But a miracle happened…A light at the end of the tunnel…Supercub.Org.

A wealth of smart people helping each other at finding solutions to a myriad of problems and giving a chance to beginners like myself to reach the ultimate goal…Flying what you have built!!

I would like to take this opportunity to thanks Bill Rusk for putting together 2 great threads about building a Smith & Javron Cub loaded with photos which are very inspiring, Christian Sturm’s Experimental Supercub project web page, Olibuilt with his red devil and all other members pitching advices & tricks to help in this adventure. Thanks to all of you, enthusiastic Cub builders and drivers!!

Let’s start this project!

I bought few parts from Jay (Javron) and one of them is the Elevator Trim Yoke. So, I decided to make the Elevator balance cable pulley housing.


First DrawingDrawing to metalPortable Metal Saw (Milwakee)
012.jpg012B.jpg013.jpg
013B.jpg013C.jpg027A.jpg
030.jpg30-04-2017 001.jpg30-04-2017 003.jpg
Voilà!​

Jay Desrosiers makes beautiful parts for our Cubs!
More to follow...
Dan
 

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Folks,
Retirement at last!! Happy not because I did not like to fly, Nooooo…Happy because I’m finally starting a long-time dream about building an airplane…Not any airplane but a PA-18 Supercub. A bit about myself, 45 years as a pilot including 30 years in the Canadian Forces, experimenting all kinds of toys Jets & Helicopters (even a stint on F-104 Starfighter – that tells you a little bit about my age!) and lately 8 years in UAE (Dubai & Abu Dhabi) flying offshore & VVIP on AW139.

Now, the real stuff! This thread will be about the building of a Supercub kit provided by Nick Smith of BBI Aviation (http://bbiaviation.com) located in Ontario – Canada. So to start with, I pretty well did like everybody else, which is reading everything referring to the Supercub then I ordered the Northland CD, studied it and went down to Nick’s place to talk aviation. Nick & his son (Nick Jr) are simply gentlemen! Nothing is complicated with the Smiths and they’ll add any modifications to your project with no additional charges!! I was hooked and order a kit!

Upon my return, (I live on the South shore of Montreal), I built a workshop in my garage and bought a bunch of tools just to look like someone who knew what he was doing. Now, this cub will have a 0-360 pulling the beast with pretty well all mods available today for this type of aircraft. I’m planning to cover it with the Stewart System due to the fact that I’ll do it at home and want to stay married for a couple more years.

I am a first time builder...so I will post a bunch of photos of my project and rely on you guys to point me in the right direction if you see something that just does not make any sense or simply suggesting a better / easier way to do things! So, here we go…

Dan

View attachment 49499
Visiting BBI Aviation with Nick Smith in his shop (fuselage section)

View attachment 49500
Wing Workshop

View attachment 49501
Now, let's make an opening for the new workshop at home

View attachment 49503
Wife said: OMG!!

View attachment 49504
Getting there...

View attachment 49505
Wife said: OK carry on!

View attachment 49506
Garage ready!

View attachment 49507 View attachment 49508 View attachment 49509
Worshop ready!! Fumes & dust meet your friend!

More to follow...
Dan
Awesome to see, Great People. Nick provided me a Cub at a great price. Great to see these pics of a guy who has a great heart and made it happen for me. I will follow Your Journey. Request me on Facebook to if You do that sort. Thank You for Sharing.
 
Good morning Dan! I build carbon fiber floor panels. Saved 10 lbs (!!) over the std wood ones. If you’re interested, I’ll put together a PDF with pictures, materials and steps to help you. Ted
 
Good morning Dan! I build carbon fiber floor panels. Saved 10 lbs (!!) over the std wood ones. If you’re interested, I’ll put together a PDF with pictures, materials and steps to help you. Ted

Thanks Ted for your offer! That would be really cool to see what you've done with these panels!
 
Mr. Carboard, come here!

Now that I have sheets of aluminium in stock, I may as well start cutting out carboard panels

Let's kick it! Upper baggage areaLower baggage area - A moose could fit there
Panel Cardboard (9).jpg Panel Cardboard (17).jpg Panel Cardboard (20).jpg
Cool fit
Panel Cardboard (28).jpgPanel Cardboard (34).jpgPanel Cardboard (35).jpg

Well that was fun!
Cheers!
Dan
 

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Upper Cabin Area

Now templates for the upper cabin area. I know that for most of you it is not the highlight of the day looking at pics of of guy cutting out cardboards. So let’s put a little smile on our faces with this quote: ‘’Taking a dog named Shark to the beach…Is a bad idea’’

Panel Cardboard (23).jpg Panel Cardboard 039 (32).jpg Panel Cardboard 040 (1).jpg
Wooden blocks (Oak) - waterproof Need space for Flap & Trim cables... Also for the fuel lines behing the back wall
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Enough room overhead?? Not sure...

More to follow...
Dan
 

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F72FB47E-A605-466A-973F-4DCD98B8119E.jpegCongratlations Dan
you look like your set up to make things happen. I have the April center fold in the Super Cub calendar and it’s a Smith cub. I never built it but enjoy flying it. Will follow your progress. Good luck.
Floyd
 

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Floyd,
Thanks for this beautiful picture, a real morale booster! If you don't mind, I may request from time to time specific pics from you about a system / installation that I can't figure out. Lots of surprises around the corner waiting for me...
Dan
 
So let’s put a little smile on our faces with this quote: ‘’Taking a dog named Shark to the beach…Is a bad idea’’

more to follow...
Dan

I never saw a problem with that, It makes for a much less crowded and hectic day once the few left settle down.
 
It could be the angle from which the photo was taken but I'm planning to have a skylight. Take a look at this picture, the cardboard stops at the passenger seat. Thanks for the advice! Dan

Panel Cardboard 040 (4).jpg
 

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