Warbird Information Exchange

Wait for it...DONE!!! Check aileron hinges off the list. These are the new outboard pieces. Center and inboards have all been refurbished, all new fasteners, nutplates, etc. These will go to MaxAero, our new aileron "Meister" to be used when he needs.

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"There are old pilots and bold pilots but few old, bold pilots."

So, how good does it feel when you get a mystery part sent to you to replicate (thanks Drew at CASC) that was missing from our project and then salvage a part number from it that yields the drawings for the assembly as well as all individual components from our 37,000 drawing inventory. Now, all that is left is...LH shown, RH opposite, make them...

Center section oil cooler door shoulder...






Found the part number on one of the pieces, tracked down to the assembly number, found in our 37,000 drawings...happy happy

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"There are old pilots and bold pilots but few old, bold pilots."

Sabre progress...Cockpit panel rework. Back to dark gull grey paint. Had to rework the placard but couldn't remove it as the pulley mechanism was riveted over the placard rivets. Actually could have but cost/benefit said nope.







Started polishing, for the first time, the wings previously painted. Yup, having fun now!

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"There are old pilots and bold pilots but few old, bold pilots."

Huh? Wha?





Geez, I'm a Dork! Jack, uh, uh, uh, or I'll take back your pony.

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"There are old pilots and bold pilots but few old, bold pilots."

Meanwhile, back in the Corsair division...

OK, no laughing from the real restoration shops. I'm just trying to work as simply as I can. The problem is, here is the LH oil cooler door shoulder on loan from CASC but due to be returned very soon. Here is how I preserved the form for my use when I get to making these. Basically, made a fiberglass splash of the skin shape. Then used that to make a fiberglass replica of the skin. I will trim to the size but know that I will have to leave excess skin to fit our AC. Am still going to have to mirror image somehow as I do not have access to the RH shoulder.

Shoulder waxed and PVA'd


Fiberglass lay up and trimmed


Flash mold pulled from the part




Then laid up a part in the flash mold


Mold and part


Shoulder and copy




Now you can start laughing at me

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"There are old pilots and bold pilots but few old, bold pilots."

Sabre Division...

Cockpit panels, cont'd




Knobs...






Panel added by Corporate Jets for target towing




Request was for a new one

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"There are old pilots and bold pilots but few old, bold pilots."

Cool stuff Scott.
Hey! I've got a great idea. Why not just put the fibreglass part on the Corsair and be done with it?

BTW, where is the sarcasm emoticon?

Andy

This thread continues to be amazing. Thanks for documenting your work Scott.

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Scott Rose
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Thanks for the kind words, Scott. I will continue, of course.

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"There are old pilots and bold pilots but few old, bold pilots."

Artists at work. Thanks for the inside view of how you guys do it.

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Well if I can't rollerskate around my playpen while smoking and drinking a beer, I'm staying home..

More "Done" Corsair bits. Steel bushings installed. Cooler door position link clip fit. Prime, squeeze the rivets, put on the shelf.

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"There are old pilots and bold pilots but few old, bold pilots."

Drove the Battlestar to the shop in the snow today. Handles just like a good heavy RWD station wagon should.
Finished the Corsair oil cooler door actuator brackets and primed them. Then after a few more layers of fiberglass on the cooler door inner skins, we reworked the F86 drop tank sway braces and got them painted. A good day.





Just follow the instructions...

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"There are old pilots and bold pilots but few old, bold pilots."

Old school polyester resin 3D printing...

Ha! Bet you thought this would be high tech. Making sure I capture all the contours I can from the sample bits. As I said in an earlier post, I am laying up a mold portion first. Then I make a replica of the skin contour I wish to preserve. I can then use to make shaping bucks or other tooling. Love the smell of polyester resin in the morning...

Laying up on the actual part


As I mentioned earlier, I then make a part from the mold so I wind up with a fiberglass replica to retain the original shape


Cooler door inside skin mold




Outer door skin molds

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"There are old pilots and bold pilots but few old, bold pilots."

Laid up more FG on the Corsair skin molds then headed to RFD to work on the Sabre main gear wheel wells while the wings are in the cradles. These are just crap with a blast of silver paint over the remnants of dark green. They painted everything so this has to be surgical stripping in order to get what the desired result needs to be.







F86 drop tank cradles

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"There are old pilots and bold pilots but few old, bold pilots."

So it's been over 30 years since I last gas welded aluminum. I have an upcoming need on the Corsair project so I thought I'd dust off my skill set today. Took a few hours and some scrap but I think I got it back. Now to work on some thinner materials.

Tack welds


Practice


After a couple hours of practice


Backside penetration

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"There are old pilots and bold pilots but few old, bold pilots."