B-17G "Chuckie" Update

[Second Air Force]

In Bill's last photo of the intake system you can see a box with some linkage on it. That is the diverter box that either admits filtered air or ram air direct from the wing leading edge intake to the induction system. In a long ago time I rebuilt one of those for TR. It's kinda complicated when you get it all torn apart...... Here is what they look like inside:


I'll probably do a battery tray "in progress" later.

S

[Holedigger]

Very cool! Thanks for keeping the pics flowing. Complicated bird for indeed, I shudder to think of how many hours it would take to build just that air flow box from scratch!!! Multiply that by xxxxthousand times and you have the time it takes to do a full restoration!

Just how big are those pesky bolts causing all this trouble?!?

[CrewDawg]

They vary in size up to about 3/4" in diameter and about 4" long. Mostly made out of unobtainium.

[Sabremech]

Bill, Scott and crew,
Great job as always, Keep the updates coming. Are you looking for any little Sabre bits I should be aware of? We start our inspection on the Skyraider Nov 16 and the Sabre rolls in the first week of Dec. We'll be busy up North.
David
WHF Maint

[CrewDawg]

Well David, now that you mention it....I dont' think it qualifies as "little bits", but a nice freshly overhauled engine, some actuators, inboard gear doors, nose torque links, and, and, and,....................

As you can see, right now we're focused on the Fort, but we're always keeping an eye out for Sabre stuff. Besides the obvious that you already know about, can't think of anything in particular. Looking forward to seeing some pics of your Spad, and Sabre, and Scooter, and, and, .....

Coming back down to Texas anytime soon? I'm at FSI at DFW now, give me a shout if you happen to come down for training.

[Sabremech]

Hi Bill,
I'll keep my eye out for tidbits. I'll be at FSI at DFW on Monday. I'll try to come out to the museum while I'm in town.
David

[Second Air Force]

I suppose it is time to get back to doing updates. During the inspection process on Chuckie the left battery support tray was found to be corroded. The "anti-fouling" paint evidently wasn't applied quite as thickly on this tray versus the two in the right leading edge--they look great. Here are a few photos of the damaged unit after removing it from the wing:




Since there was damage on the base and horizontal supports I decided to manufacture new pieces to replace the corroded parts. Here are the components clecoed in the airplane after I fabbed them.
Top view:

Bottom view:


For a change, there is lots of room to work and really good access since we had the leading edge intake removed for the spar AD. The battery is normally accessed through the Dzus-fastenered upper wing door.

The new parts laid out, then clecoed together, and finally, being shot together:




Here are two of the four original support angles that I'm able to re-use. Notice the part number on the first one and the Vega inspection stamp on the second:



While I'm sort of on the subject of rivets, I'll demo how we use a rivet cutter. Ideally, we would have a stock of every different length rivet that we could possibly use for any given project. In the real world that isn't always possible. The VFM parts room has a LOT of fasteners in stock that are the correct material and diameter for the battery tray, just too long. Rather than go out and buy shorter ones when I have plenty of the long ones, Pat loaned me his rivet trimmer:


It's pretty simple, just determine the grip length you need and rotate the correct number of stops to hold the rivet at the right position:


Here is how it looks from both sides before you squeeze the handles:



And the final product, ready to shoot:


The tray is primered and ready for the battery box paint. We'll shoot it back into the airplane after the spar AD has been completed as it gives us extra access for those two terminal fittings.

More later,
Scott

[RAMC181]

Nice bit of restoration and fabrication there Scott.

That old tray looks worse than some I've found in hedgebottoms over here that have been sitting there for the best part of 60+ years.

Keep up the good work,
PB

[Second Air Force]

I suspect there was a seeping battery somewhere in the past that got the process going, Paul. Fortunately there is no other evidence at all of any corrosive spill in the leading edge. The compartment was given a very good coat of anti-fouling paint that seems to have done its job.

[Holedigger]

Looked like the old battery tray area of my old VW Transporter! Good job on the new tray!

[the330thbg]

Scott, I like your posts!!!! They remind me of what Gary would have posted.., a do it yourself B-17 restoration!!!

Cheers, Mate!!!!!!!

[Second Air Force]

Thank you for that generous compliment, Smis. I learned to do updates from Gary when we were helping him with the B-24. In fact, his early Diamond Lil posts were the reason I became a member of the WIX family and got involved with his Ol'927 project. This is the first maintenance update that I've been able to hack together since his passing. It was a little tough to get started..........

While we're on the subject of updates, here's a photo of the old and new trays together. Notice that the original has button head rivets holding the tray to the supports and the replacement is flush riveted. Pat Mahaffey pulled up the engineering drawings for this tray and the use of flush rivets is an option on the blueprint. We went with them so that the battery will ride on a completely smooth surface. The two clecos are holding on the forward vertical supports that have to be installed after the tray is positioned in the wing.


I'll try to get back in the saddle,
Scott

P.S.
I once had a '64 double-cab pickup, Chris. The corrosion in the battery box was so bad I had to cut out the whole corner of the quarter panel to fix it, louvers and all!

[Django]

Lookin' good Scott. I thought of Gary too while I was reading your update.

That's cool you could save the pieces with the stamps and serial.

[the330thbg]

The highest compliment indeed Scott!!!!!!

[hawkeyepoole]

I see Scott H's post on his battery box build and am embarrassed that I shot video of same almost a month ago and just lost it in my multi-terabyte video farm. Found it! Here's a little short of Scott and his new box. More vids when he finally installs it after the spar work.

I'll shoot video this weekend if there's any spar AD activity or other activity that I think might be interesting. Post here or email me at franklin@pgctv.com if there's something you'd like to see about/around Chuckie or the Vintage Flying Museum.

DOH! almost forgot the link to the video: http://www.vimeo.com/7737110