Design and Development
The Custom Flight North Star emerged from designer Morgan Williams' vision to create an improved version of the iconic Piper Super Cub for the amateur-built aircraft market. Development began in the late 2000s with the goal of enhancing the already exceptional short-field capabilities and slow-flight characteristics that made the Super Cub legendary among bush pilots.
Williams incorporated several key innovations into his design. The aircraft features a welded 4130 steel tube fuselage construction combined with aluminum-sheet wings covered in doped fabric. The high-wing configuration utilizes a USA 35B airfoil across its 36.3-foot span, optimized for low-speed stability and control authority. The tandem cockpit measures 29 inches wide, providing enhanced comfort while maintaining the traditional bush pilot seating arrangement.
Production History
Custom Flight began kit production around 2011, with the first completed aircraft taking to the skies the same year. The company, operating from Perkinsfield in Tiny, Ontario, experienced steady demand from amateur builders seeking an authentic Super Cub experience with modern improvements.
Production numbers tell the story of gradual but consistent growth. By December 2011, 20 aircraft had been completed and flown by builders. This number grew to at least 24 examples by 2014, with registration records showing 27 aircraft on the Canadian register and 13 in the United States by December 2015. Interestingly, some early examples were completed as far back as 1998 by Ontario builders including D.E. Blackburn, A. King, R.M. Harkness, and W. Smith, suggesting prototype or pre-production development occurred earlier than the official 2011 launch.
Technical Specifications and Performance
The North Star's performance envelope closely mirrors its Super Cub heritage while offering improvements in specific areas. Standard power comes from a Lycoming O-320 engine producing 150 horsepower, though the design accommodates powerplants ranging from 150 to 180 horsepower. A variant designated the North Star 180 utilizes the more powerful Lycoming O-360 engine, increasing empty weight to 1,338 pounds while enhancing overall performance.
With its standard O-320 engine, the North Star achieves a cruise speed of 115 miles per hour while maintaining an impressively low stall speed of just 25 miles per hour. The aircraft's rate of climb reaches 1,100 feet per minute, and its 52-gallon fuel capacity provides a range of 690 miles. These figures translate to exceptional short-field capability and extended loiter time for bush operations.
The aircraft's dimensions reflect its practical design philosophy. At 22 feet 6 inches in length with a wing area of 190.7 square feet, the North Star maintains manageable ground handling characteristics while providing the wing loading of 12.3 pounds per square foot necessary for slow-speed operations. Maximum gross weight reaches 2,350 pounds, though this increases to 2,300 pounds when operating on floats.
Operational Characteristics
The North Star's versatility extends beyond its performance numbers to its operational adaptability. The aircraft can be configured for wheel, float, or ski operations, making it suitable for year-round bush flying in Canada's diverse terrain. This multi-season capability has made it popular among recreational pilots and bush operators who need reliable access to remote areas regardless of conditions.
Aerobic capability adds another dimension to the aircraft's appeal. Unlike many bushplanes that sacrifice aerobatic performance for utility, the North Star maintains structural integrity for basic aerobatic maneuvers while retaining its short-field characteristics.
Market Position and Legacy
The Custom Flight North Star occupies a unique position in the amateur-built aircraft market by offering builders the opportunity to construct a modern interpretation of one of aviation's most beloved designs. With an estimated 1,200 hours required for kit completion, the project appeals to serious builders willing to invest significant time for exceptional results.
The aircraft's influence extends beyond its production numbers through its contribution to the kit-built bushplane category. By proving that amateur builders could successfully construct aircraft matching or exceeding certified aircraft performance, the North Star helped validate the homebuilt movement's technical capabilities.
While Custom Flight's operational status beyond 2015 remains unclear, the North Star's legacy continues through the aircraft still flying throughout North America. The design represents a successful bridge between aviation's golden age of bush flying and modern amateur construction techniques, preserving essential flying characteristics while incorporating contemporary materials and construction methods.