New Corsair Spars, Another Thread!

Craig · **Posted:** Sat Oct 10, 2009 7:07 pm

Since the video story on our efforts to restore the Corsair here in Connecticut was posted on this site, http://www.warbirdinformationexchange.o ... hp?t=32406, and has generated interest, I thought I would try and answer a few questions. Here is the other thread on the Corsair Main Beam subject:
http://www.warbirdinformationexchange.o ... hp?t=32406
Some have asked about our ability to fabricate the Corsair Main Beam. Our staff is comprised of professional A&P/IA mechanics, aeronautical and mechanical engineers, and professionals all experienced in their areas of expertise. What we cannot do in-house, we send to FAA Certified Repair Stations, or our staff verifies the processes have met FAA standards. All materials are obtained with Certificates of Conformance. The work we do is in accordance with all technical orders and FAA approved practices.
We have modeled the entire Corsair Main Beam components and the entire assembly in a 3D CAD program. Every component is now digitized, some having been manually created, and some created through scanning. We fabricated one test main beam using rapid prototype components. We are fabricating all new forgings and extrusions and are using custom ordered material in the correct dimensions for the sheet metal and plate components. Initially, we were just going to make the parts we needed to replace, but decided to make all new components. Being in Connecticut, the original manufacturing location for the Corsair, we have no shortage of qualified shops. In fact, Connecticut has over 1,000 aerospace and defense manufacturers. We have designed and are building a new main beam assembly fixture, and are now completing our center section assembly fixture.
One could write a book on the design and construction of the Corsair Main Beam. It is truly an engineering marvel, and one of the most complicated structures to fabricate. We did not intend to go as deeply into this aspect of the Corsair as we have, but now that we are here, one of our major priorities is to work with other restorers and shops and help each other out. Our goal is to restore our aircraft, and help as many other projects along as we possibly can. As the old saying goes, “Cooperate and Graduate”.
Anyone interested in speaking with us to discuss this subject feel free to email me at craig@connecticutcorsair.com.
I hope this answers the questions!

Craig

Jerry O'Neill · **Posted:** Sun Oct 11, 2009 10:24 am

Thanks for chiming in Craig!
You've answered a bunch of question some of us have on the process!Good luck!
Jerry

Craig · **Posted:** Sun Oct 11, 2009 11:19 am

Thanks Jerry.

Also, thanks to those who wrote me to discuss this. Another question that came up was the software we are using. The 3D CAD program is called SolidWorks, www.solidworks.com.

RMAllnutt · **Posted:** Sun Oct 11, 2009 11:49 am

Solidworks is an amazing program! I use it nearly every day, and it's one of the simplest, and most powerful 3D modeling programs I've ever used. It's good to know you're using it too Craig!

Cheers,
Richard

VCS1 · **Posted:** Sun Oct 11, 2009 2:12 pm

As someone who is also using 3D modeling and reverse engineering technology, I am very impressed with this effort. In my case of building a P-35A replica using modern technology, I was always trying to find "factory" pictures of how the aircraft was built originally. As a result I have accumulated data on a variety of aircraft in my search. Here are some scans from World War II magazine on the production of the Corsair. I hope the pictures may help you with your effort.

RMAllnutt · **Posted:** Sun Oct 11, 2009 2:26 pm

WOWWWW!!! These are absoultely fascinating images/details. Which magazine (and issue) did they come from, and do you have any more? I have seen very few detailed images of corsair manufacture. Usually, just the production line shots, which show the bigger picture. I do have a few shots of corsair main spar manufacture somewhere. I will have to dig them up when I get home in a week or so. Please keep posting though... these are fantastic!

Cheers,
Richard

Holedigger · **Posted:** Sun Oct 11, 2009 3:24 pm

That main spar is such a heavy duty monster, it must weigh close to what the entire fuselage of a Zero weighs!

VCS1 · **Posted:** Sun Oct 11, 2009 4:31 pm

I am glad you liked them. They are from the November 1943 issue of "Wings" magazine. Since this was "part 1" of the series, I am looking through my collection to see if I can find "part 2".

RMAllnutt · **Posted:** Sun Oct 11, 2009 4:52 pm

VCS1 wrote:

I am glad you liked them. They are from the November 1943 issue of "Wings" magazine. Since this was "part 1" of the series, I am looking through my collection to see if I can find "part 2".

Many thanks!!! I hope that you have it!

Cheers,
Richard

Craig · **Posted:** Sun Oct 11, 2009 4:55 pm

What a great article! Thank you so much for posting it. I have seen bits and pieces of some of the fixtures from production line photos, but not a published article such as this one.

Richard, we look forward to the spar photos you mention, I do not recall ever seeing them in my research.

RMAllnutt · **Posted:** Sun Oct 11, 2009 5:08 pm

Craig wrote:

What a great article! Thank you so much for posting it. I have seen bits and pieces of some of the fixtures from production line photos, but not a published article such as this one.

Richard, we look forward to the spar photos you mention, I do not recall ever seeing them in my research.

I definitely will... won't be home for more than a week, so please remind me if I forget! I'd love to see some of your images if you are able to post them too.

Cheers,
Richard

Craig · **Posted:** Sun Oct 11, 2009 5:24 pm

We are in the process of completely re-building our website, and our volunteer webmaster is adding photos, images and other information as best he can. Once we get the site up and running properly, it will be updated on a regular basis.

RMAllnutt · **Posted:** Sun Oct 11, 2009 5:43 pm

Craig wrote:

We are in the process of completely re-building our website, and our volunteer webmaster is adding photos, images and other information as best he can. Once we get the site up and running properly, it will be updated on a regular basis.

Really glad to hear it Craig, as I'm sure this will be a real draw for your benefactors... not to mention us!

Looking forwards to seeing your progress!

All the best,
Richard

Rob Mears · **Posted:** Sun Oct 11, 2009 6:55 pm

I can post "Part II" if you can't find it. Its from the December 1943 issue and its 'main spar' specific.

Warbird Kid · **Posted:** Sun Oct 11, 2009 7:06 pm

I've been away for like, one day and then THIS thread comes along! :wink:

Awesome to hear it straight from the source Craig! And hope to see you down at the museum soon too! If your not there, I don't think were ever going to disassemble that dang Corsair!

Actually the reason of my tardiness for not chiming in sooner on this thread was that I was at a local model train show with a booth setup for our own Corsair. (The other one) :lol:

and the CASC.

Made $88 today. :oops:

Not alot, but its a little more than what we had for the museum.

Okay, back to the super news about new components for our favorite fighter!

Christopher

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