Bushcat Build Log

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

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.