Gary ~ What's The Plan For Diamond Lil ? 2006 and Beyond!

[TimAPNY]

Great work. Very cool that we get to see it come together. Thank you very much for letting us watch the progress!

Tim

[bdk]

I agree! This is far more interesting than all the other posts on this site combined. Real time get 'er done warbird restoration action!!!!

[Eric Friedebach]

What those guys that posted above me said.

This is the kind of stuff that makes WIX great!

[retroaviation]

Thanks guys. I'm not getting much built today (only one piece so far). I've simply got too much clerical stuff to do. You know, phone calls, parts ordering, package shipping.....the fun stuff.

Gary

[TAdan]

Great work Gary! You make it look easy

Thanks for keeping us updated.

[Jerry O'Neill]

How come nobody suggested it be re-painted in it's old PEMEX colors?!!!
It spent most of it's working life doing that kind of work.

Just kidding!!
Great job and I love the updates.
Thanks so much and good luck with the conversions!
Blue skies,
Jerry

[retroaviation]

One tailgunner's window & frame fabrication complete...............




Now it's time to do it again with the other side.
Gary

[Dan K]

Lookin' good, Gary. Lookin' real good.

I have zero experience working with acrylics, and my tired, old eyes can't quite make out the product name of the window material you're using. I'd be thankful if you'd elaborate on what you're using, and why you prefer using it.

Or is that just a hunk of cardboard you're using to get the fit right?

TIA

[retroaviation]

Lookin' good, Gary. Lookin' real good.

I have zero experience working with acrylics, and my tired, old eyes can't quite make out the product name of the window material you're using. I'd be thankful if you'd elaborate on what you're using, and why you prefer using it.

Or is that just a hunk of cardboard you're using to get the fit right?

TIA

Excellent question! That is the protective coating on a sheet of polycarbonate plastic...better known as Lexan. Well, actually, this is a different brand name, but still the same stuff. The Lexan type products are good in the fact that they're quite strong and can be bent in virtually any configuration (with some effort). I don't have a large enough oven here to put the blanks of these particular windows in, so I just used one of those jet-style heaters to warm it up. Then, as a fat boy, I was able to "lean" on it a little bit to get the curve I wanted. What you see in the previous pictures is my third attempt to get it right, and if the optics aren't quite as good as I'd like when I take the coating off, I'll probably make another one, until I'm satisfied. I'll get someone to take photo of the process in which I bend the next one. The downsides to Lexan type products is that it's expensive and it tends to craze a little faster than the acryilc type products. I'm sure there are other "goods and bads" with this stuff, but that's all I can think of at the moment.

As far as the "cardboard" portion of your comment goes, that is also a good question. I do indeed use posterboard to get the exact size and shape of the part I'm building in order to keep from wasting sheet metal and time. Below is a photo of the posterboard piece I'm working with right now. This is the "Mk.1,Mod.1" version, as I still have some trimming and other adjustments to make, but I think you'll get the idea.


By the way, keep the questions coming! I ain't skeered.
Gary

[krlang]

Gary,

What do you do in your spare time?

[Dan K]

Thank you, sir.

So do you dimple the posterboard before or after the fitting process?

Oh yeah, what thickness Lexan are you using?

[retroaviation]

For these particular windows, it's 1/8" Lexan. Most of the others in this airplane will be the same. Others will be 3/16".

I'm afraid there is no spare time for me. Since there are virtually no volunteers, I work every day from 3 am until at least 5 pm. Sometimes as late as 8, but not very often. The B-29, B-24, and Testiclese could suuuurrrre use some helpers.

[Dan K]

I'd be there to buck & rivet now if the commute wasn't 20 hours one way!

[retroaviation]

The tailgunner's upper windows & frames are both finished with fabrication now. Here's how the process went (starting just after the previous pictures)...








It's kind of starting to resemble a B-24A tailgunner's compartment, huh?

Gary

[Robbie Stuart]

Looking real good Gary. I envy your talent.
Robbie