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Thread: New 2 person Challenger build.

  1. #1
    New Member
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    Oct 2018
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    New 2 person Challenger build.

    Hello All,
    Starting a new build for my neighbor. He rode in my mini, got out and said how much and how long for a 2 place ?. He’s a Dr. and can afford questions like that.
    Well, I traded him my Challenger II airplane for his Bush Trike ( ultralight). Now will cut the tail, take off the wings and basically bolt the main cab and power plant (rotax582)into a 5x10 1/8” hull. Tig welding the hull together now.
    5052, .100” 5x10 aluminum, with 1”, 1/8” square tubing braces. Main hull will be flat bottom with a little bit of a wedge in the front transitioning to straight and flat on the back half of the hull. 18” sides with a little bit of a softening chine towards the rear, but mainly this is being designed as a carving boat, with a little bit of slide, when needed . Projected weight of 500 lbs all up. With seating for 2 and lots of storage for gear.
    The Challenger airframe will be mostly intact with very little changes.. twill be taking a few things out, off. For the most part it’s a bolt in and go operation.heater, removable windows, intercoms, seatbelts, electrical, gauges, etc....is already done !
    I’m hoping to get it done in a month. I’m 1 week in and will be posting pics soon!
    Last edited by Jssflyer; 04-15-2019 at 11:42 AM.

  2. #2
    Super Moderator Corky's Avatar
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    Jul 2014
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    Susquehanna river, Dauphin, Pa
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    Re: New 2 person Challenger build.

    Nice, looking forward to the build...

    Aluminum .120 14' X 76" hull
    Teledyne 4a084-4 engine
    Circle S 1.69:1 reduction
    67" Whirlwind "Razor X" prop



  3. #3
    New Member
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    Oct 2018
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    Re: New 2 person Challenger build.

    A change of plans...not using the Challenger frame. Just the engine and instruments. Rotax 582.
    The build is going good and should be done in a few weeks. Going to turn out like a cross between a mini jet boat and a traditional airboat. Will have bench seating for a couple kids as well as as the primary driver seat.heres a couple pics of the hull. Name:  14EC7FDB-7D8A-4DA4-BE39-4973028B22B9.jpg
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  4. #4
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    Oct 2018
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    Re: New 2 person Challenger build.

    Update on the mini.. going good. Getting better at Tig welding, kinda. Am now building the top half, and drilling for rivets on the top thin stuff. Installing the seat, cockpit, gauge plate today. Couple pics.Name:  AAB17E2E-E74F-435D-A670-D368429C2A79.jpg
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  5. #5
    New Member
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    Oct 2018
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    Re: New 2 person Challenger build.

    Hello, after a few months of farming I’m back into the airboats. Finishing up the Challenger build. And already started on a new 4 x 9 ft. Mini with a 503. Couple of update pics on the Challenger build.Name:  1378FB7B-5D50-429B-ABD4-DFB3B2DE0917.jpg
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  6. #6
    Member Bart's Avatar
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    Valdez, Alaska
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    Re: New 2 person Challenger build.

    looks like you have got that tig welding figured out and things are looking good. What did you end up using to bolt the UHMW to the hull, & what thickness did you end up using? I am thinking it may be something that I will be investing in.
    with a 582 power plant, it should be a fun one..

  7. #7
    New Member
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    Oct 2018
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    32

    Re: New 2 person Challenger build.

    H Bart,
    I put 1/4” uhmw on the bottom with 1/4x20 x3/4” SS countersunk screws. Used a drill and tap bit and marine 5200 sealant. And it doesn’t leak ! I was impressed and surprised. I am repeating the same process on the new hull I’m building now. We should get to do some testing on this sled in a few days. Will let you know how it does.

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