Airdrome Airplanes Sopwith Pup Project

[RAF56_Ball]

At RobW's recommendation, I am starting this thread. Its purpose will be to document the building experience (such as it is) of a Robert Baslee (pronounced like ‘Boz-lee) full scale aluminum and fabric version of the Sopwith Pup, share the ideas I have for this project and more importantly, chronicle the thoughts and suggestions that you have.
The standing link to construction pictures will be:
Airdrome Airplane Pup

Already I have a question to pose to the group. Did the RFC use the CDL- sided fuselage on any of their planes? The RN seems to have used it, but have not found info re: RFC use. OIn that line, has anyone seen images of the RFC using the vertical fin in CDL and “the Sopwith Aviation Company Ltd.” “Kingston on Thames” logo? I like the look of this, but will be doing a re-enactment of an RFC pilot, so want a more authentic look. Something in 60 Squadron would be nice, as I could make at least a circumstantial case for Ball having at least seen one.

I have a copy of the Winsock Sopwith Pup by J. M. Bruce. I have access to “Sopwith Pup Aces of World War 1” by Norman Franks as well. The pictures in them seem to confirm that only RNAS used that tail logo, but I hold out hope that some of you have better information or more extensive images or sources I can reference.

So the journey begins.

[RAF56_Ball]

(for March 2&3, 2009) I promised a bit of banter for the forum about me visit to Rrroberrrt’s Airrrdrrrome Airrrcrrraft Shoppe. Sorry, being around so many reproductions changes one. Mind switches from a British to German accent, don’t you know. Frightful. And one begins to enjoy Monty Python and Blackadder as well.
Okay, so maybe that is a stretch. But it is no stretch to say that the guys there, Robert, Jim and Dave, taught me more about how to build one of these kits and did more for my confidence than I could have imagined. Well worth the trip, and then some. It went something like this:
It was a blessing that Jeff Basham and Scott Nichols had just been. The Comfort Inn is the place to be. It is closest to the highway out to Robert’s, close to food and has good pricing.
Things started simple enough. “Robert, I’m in Holden with a box of doughnut for you guys. Where are you located?” Did I mention that I tried to find my way there without the GPS OR and forgot to bring the address? We kept missing each other on the phone. So I got there closer to 9 than 8. We jumped right in, laying out the drawing of the fuselage (funny, it looked bigger at EAA when I sat in Scott’s – or so I thought until it was 3D - BIG bird!) Tubes are sorted by pre-marked numbers. Then Robert handed me a bucket with a bunch of wood blocks, instructs me on the idea, points to the plan and turns me loose. Jim (bless his understanding heart) guides things so I don’t put them in the middle of a tube or gusset. Then we make 4 long tubes out of 2 different sized ones (they fit one in the end of another, then are riveted together – “berry strong dat way, sahib”!) THEN the first heart stopping moment comes. We cut a tube! Then another. Then we (I can’t look) BENT ONE!
Robert explained every step as we did it together, calming fears and answering questions that I haven’t even been able to formulate yet. He does it without letting the work pace slow, yet things were done correctly. That takes a deep understanding of the process, and a heart for those you are helping. It was a thing of beauty and a joy to behold. Jim is a wellspring of practical tool tips, safety and building ideas. He only had to remind me 1 or 2 (hundred) times to “waggle the drill” more. I was being too careful to go straight in and straight out. While a drill press would have made spacing perfect, as I learned, none of the time wasted making perfect holes does anything for the build; waggling (carefully) deburs the hole (and helps the Japanese rivets fit in the American drill-bit holes per Jim).
A single rivet is strong enough to hold any joint here. The second is for stability and alignment. The 3rd helps the looks and the 4th is for added strength and redundancy. Ask Robert about clusters and multiple gussets. Even the most wary will realize that this is a well thought out “tried and true” method of construction that is perfectly suited for these types of planes.
Oh, and you don’t need to shake all the filings out of the frame – they polish the inside preventing corrosion (Robert, says tongue firmly in his cheek), and act as attitude indicators for all three axes (Jim, you are so wise). In a high speed high ‘G’ plane they might mean something, but nothing here.
Back to the program! We cut and coped vertical tubes doing them in pairs, coping to fit, bending some others – “don’t worry about the bend, we only need the tube to be straight down here for the wing carry through” setting one of the pair off to the side. As we fit pieces in we put on gussets and start to drill holes. With at least 3 air hoses, things move along. Somewhere in all of this orchestrated chaos we paused for lunch. Afterward we jump back in, finishing a side. Soon a visitor arrives. Rob Waring from Great War Aerodrome (and a future builder once he decides which plane he wants) is there for a meeting at Leavenworth, but he is the only one that got in – rest got stuck by weather back east. (Rob’s wife, it’s true, he didn’t come just to play at Robert’s workshop!) He willingly grabs a drill and rivet gun and we team up. Once that side is done, we flip it over, holding it in place with a few blocks. I swear to you, in about 1-1/2 hours we have the other side together using the first as a jig (remember those duplicate pieces), helped by “zip strips” and a few clamps. Then we clean off the bench, drop a chalk line and start to join/align the halves with techniques that are so simple they were revolutionary. Baling wire fit prominently in the truing up of the sides, I kid you not. We broke for dinner with most of the cross braces in place and a few cross members to go.
Rob and I joined Robert and Sue for dinner at a local Teppanyaki place (you know, they cook right in front of you and do a show of it). We talked about planes, history, plans for the Virginia Beach Show (check out Home - Great War Aerodrome), and whatever came to mind. It is the most fun I have had while being pleasantly tired that I can remember. Then to bed. I can’t even open the books I brought to read.
Day two starts a little slower. Robert got himself a new used bobcat (still think we should paint “Robert’s Kitty” on the side). It had to be unloaded after they picked it up. Some might have felt slighted, but I love anything that moves, so this was a kick for me, too. Once it gets parked (the bucket had a mind of it’s own – ‘nuff said” we get back to Mr. Sopwith’s hangar. We finish the fuselage, Robert shows off its strength, then we start on the Horizontal stab and elevator. Want the details? Watch the videos. It went just like that. Do yours EXACTLY like that and you will get things done quickly and efficiently. Suffice it to say, these are basic planes, and Robert has found a way to build them simply. Trust him.
Wednesday morning Dave helped Robert and I to put the remaining parts in the fuselage or back of my car. we wrap the framework with the longest roll of Saran Wrap I ever saw! We then cover it with a 16 X 32’ tarp, spiral wrap it with duct tape, and lash it to a trailer. Robert starts laughing, noticing it looks like the motorbike trailer from the movie “The World’s Fastest Indian”. The trip home was uneventful, and is the first time that I ever got a large piece lie this moved without the tarp being shredded.
So much had happened that I was not sure I would remember any of it. Before leaving, though, Robert handed me the builder videos. I watched those after I got back home, and was startled by how the build of the D-7 went just like the Pup, with many of the same explanations. Everything came right back to mind. The consistency is very reassuring. I have already nearly completed the rudder, and have the parts set up for the vertical fin. Next comes the gear, then the wings.
Construction is very straightforward. I have no doubts that the Pup will look just fine, be safe, fly well and be lots of fun. I encourage anyone (even without a bit of handiness - you can learn all you need in a day or two!) that wants a plane, delve into one of Robert Baslee’s Airdrome Airplanes kits. I was a skeptic that has been convinced. These “aluminum skeletons” are not just simple, they are strong and efficient. Seriously consider the builder assist program, too. It is worth the time spent just to get to know his team. Learning some new skills was gravy on the meal.

I like the methods so much, I plan to eventually build one each of the planes flown by Capt. Albert Ball, VC, DSO, including a Baslee Nieuport 16, the Bristol Scout (which is so much like a Pup it is scary), and an SE-5. A Sopwith 1-1/2 Strutter two seater would be nice someday using the same techniques. Take someone for a ride and I bet they will want one, too!

[RAF56_Ball]

April 7: Well, an update, just before I get back to construction. Was at the airport almost daily. The tail feathers and braces are done, LG is nearly done (needed some new gussets - don't ask, just make sure you properly clamp any pieces you plan to use a power tool on 8=( ), tail wheel assembly is ready to mount, the "turtle deck" is on, the rudder pedals are built (I modified them to add toe brakes), former for instrument panel is made, the firewall is about to get it's flanges, I am starting the wing build today, a temporary floorboard is in, a "bucket" seat sits on it and I am working on the controls. It is nearly time, gentlemen, for ...........

THE VROOM VROOM STAGE.

Oh, come on, all of you builders have done it. You sit in the cockpit saying you are checking control layouts and instrument panel position. Then you start making engine noises, work your head around to check field of view (and make sure the Red Baron, or Snoopy, if you are Central swine is not on your tail) and imagine the wind in your face. Even the guys that have built before do this.

They just don't drool or wet themselves as much, heheheh!
Now if I can post some pictures on my site, you can see the progress.

9 April: Planning cut out for the cockpit.

This last week I worked on shaping tangs, drilling, prepping for wing construction. On the turtle deck I made a change to the tubing layout. The kit shows 5 stringer/tubes evenly spaced at the former in front of the elevator. Pictures of the plane show that there are 2 additional short stringers, one on each side going forward about a foot, down to the upper longerons, with 5 stringers going up to the bulkhead behind the pilot. So I took two pieces of scrap and made these. Much better!

Getting ready to do the forward stringers that form the shape behind the cowl, and notice that the plans show them going to the rear cockpit bulkhead, but pictures seem to end forward of that. The vertical tubing that surrounds the lower wing rear spar carry-through matches this quite well, so I will use that, after mounting the firewall.

I also noted that the wings go right next to the box portion of the fuselage, with the streamlining (that I was just discussing) blending in above it. This will make for a cleaner wing mount, with less gap, so that change is in the works as well. It does mean doing a bit of sheet metal bending right there, but the angles are simple, no compound curves so I will give it a go.

April 11: Tail wheel mount is completed, just need to figure out the bungee stops. Getting ready to run the control cables to the rudder and elevator.
Time for Easter break.

[Bookmaker]

Nice project, Glen. I am sure you mentioned it somewhere, but what engine do you plan to use?

Dale

[RAF56_Ball]

Engine is a Rotec R-2800. It is on the way from Australia.
Been at owrk most of this week, but will be back at the Airport tomorrow and this weekend. Did get tires mounted. Smelled like a french whare house (oh, did I drop an 'o'?) as the only talc I could find was scented.

Hope to do the stab and landing gear cables tomorrow, then will get after the wing center section. Could ahve the wing basic panels done by the end of the week. Will need to make the rib bending jig this week.

[Bookmaker]

Thanks for the info.

I had considered their full size N 17 with a Rotec, but realized I would never finish it. Too many other interests.

Good luck. I'll be watching.

Dale

[Treize]

I'm keeping an eye on this one too, but I'm more interested in their N.28. Please share video of your kite when she gets into the air, we want to see her in her natural element!

[RAF56_Ball]

IT's HERE!!!!

All seven georgeous cylinders are HERE! I was surprised and very impressed with the quick delivery from Australia and the Rotec team.

Now all it needs is a completed airframe, eh?

[Bookmaker]

Chip, I was looking through your photos and came across one labled "dihedral tube" I think. That brought up a question. Looking at the photos of the completed plane, it appears the wing is basically built flat. WHat is the dihedral?

Dale

[RAF56_Ball]

The original, which is still at Rob's, I think, did have a flat wing. Rob came up with this suggestion (as an interim until he manufactures a different piece) to develope dihedral. He is going to do the same for the one seen on the Airdrome Airplanes Site.