DC-3 Display Project
I placed the first balsa order, and recieved it before Christmas in 2000. At that point, the estimated completion date was May 2001, which I have obviously missed. Over the holiday, I cut out the parts for the wings, tail surfaces, and nacelles. I packed up the parts and carried them back to school. While there, I framed up and sheeted the tail surfaces. On my next trip home, I framed the wing tips and center section, and sheeted most of the bottoms. Note the Dr. Pepper can in the picture for relative size.
At that point, I became busy with other projects, and put the DC-3 on hold for a little while. I had a few unexpected changes, including a move to Memphis, and didn't have time to work on it. Now, I have devoted more time to researching and finishing it up. I wish that I had thought about a web page earlier; I would have more complete documentation of the previous steps.
I have decided to try a material called Flite-Metal, due to the costs and end result. The material is actually real aluminum, so as the model ages it will only begin to look more realistic. With this technique I will be able to apply the material in scale panels, so the finished model will include panel lines and rivets.
Recently, I ordered and recieved the plastic dummy engines. I realized that I should probably find an aircraft to model before I get too far along in the process, since there were so many different types of DC-3 configurations. After much deliberation considering finishing techniques and costs, I have decided to go with the Eastern Airlines scheme that is on display in the Air and Space Museum. It is a civilian airline scheme, which corresponds well with our civilian pilot training. It is also nearly all bare aluminum, which means less painting and thus less hassle. I though long about the Piedmont scheme, but it is not as recognizable and requires much more painting.
Another advantage to the Eastern Scheme is the available documentation. I have ordered detailed drawings, and close up pictures depicting the actual airplane in the museum. These pictures will be invaluable, since the model will have the landing gear in the retracted position (like the museum plane), and it is nearly impossible to find close-up pictures of the DC-3 with the gear up.
At this point I have the Flite-metal, but I am far from being able to use it. As soon as the documentation arrives I will build the ailerons into the wings, and finish the construction of the wings. The next step will be to plan the windows and doors on the fuselage, and then finish sheeting it. At this point, I plan to fabricate a fiberglass part for the tail; it has some very complicated curves, and will probably be too much trouble to carve. I will try to update the progress on this page as time and motivation allow.
2-8-2002
Here are some pictures of the radial engines. I haven't put the pushrod tubes on yet, since I haven't had a chance to go to the hobby shop. I plan to use 3/32" aluminum tubes for easy texture and luster. I'll also have to figure out some way to make a prop governor; the Ziroli mold has a tab where it should go, but no actual governor.
3-4-2002
I have done a bit more work since the last update. I prepared the cowlings as though I was going to paint them; I started with a filler for the pinholes, and then sanded most of it off. I sprayed on a coat of automotive primer to check out the surface, and made a few more minor touch-ups. This provided an excellent surface.
I used the several sources of documentation to lay out the cowl flaps. The ziroli cowl had a flared flange for the flaps, but the flaps weren't actually cut out yet. This was pretty tricky, and involved much head-scratching and calculations.
After it was ready for paint, I started to apply the flite-metal. It is kind of silly for me to do the cowls first, since they are probably one of the most complicated shapes on the airplane. But, they are the only parts that are ready to cover, and I wanted to check the stuff out and see what I thought of it before I spent all of the time preparing the rest of the airframe. The verdict is good so far; I think it is great stuff. Here is a web page about my flite-metal experience. Here is a picture of the cowl, with the radial engine resting in place. I have installed the aluminum pushrod tubes, but I still need to figure out the ignition harness and wires, and the prop governor.
5-01-2002
I have prepared the top of one aileron, and am almost finished with the other. It is slow going, since there are so many ribs.
5-21-2002
After a busy weekend or two, I have finished the left wing to the point of finish sanding. That is as far as I plan to finish any of the parts until they are all ready. When I transport them around, I always find new dents and dings, so it is better for that to happen before the more detailed finishing. I sheeted the top of the wing, and installed the balsa block wingtip. I also finished the other side of the aileron with ribs, and shaved them down to match the curvature of the wing. Since the model doesn't need to be up to flying standards, I've designed a simple and cheap aileron mounting system. Each one has three toothpick supports that have enough friction to hold the unit in place without glue. This will be very handy when it is time to apply the fabric covering to the aileron.
Click Here for Construction Part 2
Click Here for the DC-3 Index
Email me with questions or suggestions!
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