Cape Town man builds DIY bush plane

He has undertaken the extraordinary challenge of building a BushBaby Explorer 2 using a Dremel multi-tool. The BushBaby Explorer 2 is a twin seat aircraft that can hold up to 70kg of luggage and travel up to 700km in one stretch. His inspiration for the project came after he learnt to fly a helicopter.

"After learning to fly a helicopter, I decided that I needed to learn to fly a fixed-wing aircraft. Once I had accomplished that, I wanted an aircraft of my own, but I could never afford it. While looking for alternatives, I discovered that it is possible to build your own aircraft," he explained.

Construction on the bush plane began early in 2014 and is due to be completed in January 2015. Frylinck emphasised that assembly of the various aircraft components requires precise and accurate cutting and placement, for which he uses a Dremel multi-tool.

He stated: "I have had the Dremel for some time, it is the only tool I use and it does everything I need. For all cutting, sanding and grinding processes, as well as any small and intricate tasks, the Dremel allows me to complete these with ease. I can solve any problems I encounter because I know the capabilities of the tool."

A variety of materials

Assembly of the bush plane requires working with a variety of materials, including: 6061 aircraft-grade aluminium, marine plywood, aluminium sheeting, and fibreglass. Frylinck reveals that the Dremel multi-tool can cut through all of these materials quickly and easily, saving time and preventing wastage, as well as damage to the material.

"When working with these materials it is vital that all cutting, sanding and grinding is accurate. If a mistake is made, the material has to be scrapped in order to meet safety regulations. All the Dremel attachments are the perfect size, ensuring that no material is wasted and that the job is precise."

Frylinck observed that building the bush plane is a family project, with his wife, son and daughter participating and assisting with the various stages of construction. "We are all involved with this project and we love it. This project has given us something we can do as a family, and gives us more quality time together."

According to Frylinck, the most gratifying part of building the plane has been the enthusiasm that the children in the community have shown for the project. "Children come over to the house to see the plane because they cannot believe that we are actually building one. I would love to start a similar project in a school, where all the children can get involved and can learn valuable skills that they can use in other aspects of their lives. It would be a valuable and rewarding experience."

Frylinck pointed out that this project has been immensely satisfying because of the interest that the community has shown. "When I work on the plane there's an incredible satisfaction that I get from creating something and doing it well. Men and women driving past the house will stop and come in to look at plane. People are shocked when they see what I am doing, and they want to get involved. It's just a wonderful community project," he concluded.