Oklahoma SE5a Project

[regular122]

Well, I finally took the plunge on constructing a replica WWI biplane. My dream since a boy is to fly one and own one. Now I may have the chance.

My interests revolve around American pilots that flew with the RFC or RAF. A great many successful and high scoring aces flew with the Brits but rarely received any recognition as American aces. A couple of them scored 20 or more victories.

The rationale of making such a replica is to make one that would cover both 1917 and 1918 in time reference. This would make it appropriate to fall in line with half of the war's aircraft. I want it to be marked British but be flown by an American to get the effect of highlighting the history of both nations.

While I still hope someday to build a Sopwith Camel, especially after seeing the magnificent work of Russ and his Camel, I took a turn when an opportunity too good to pass up presented itself.

The project I am taking on started in the 1990s. The wings came from a Currie Wot SE5a project belonging to gentleman from Pennsylvania. They are very well crafted. In 2006, the project passed to the able hands of the award-winning Roy McCladin and Brian Becker. Roy began spearheading the project to build the fuselage and other items with Brian. With Roy's unfortunate passing, the project went up for sale so Brian could focus on Roy's one of a kind DH-4 that is flying today.

I purchased the SE5a project in November 2016. It will be powered by a Lycoming O-235 C1 which came with it.

After a lengthy journey, I was able with the help of several very good friends to retrieve the project from Tucson and transport it to Oklahoma. We and it arrived safely yesterday and today I laid out the major components to determine some of the inventory, etc. I could not help laying it out with its wings for a few pics.

So, with the forum's patience and expertise, I hope to fill this thread with the construction of a Replica Plans (Currie Wot based) SE5a that will be created to appear as Harold Kullberg's Wolseley Viper-powered, Air Navigation Co. Ltd. made C1835 of No. 1 Squadron RAF.

The project will likely take years and especially so given my work schedule. I am already grateful for the tremendous help this forum has been and will continue to be and welcome any comments. I would also be grateful to hear from those with Replica Plans machines experience. Steve

[ONEALM]

Happy New Year Steve -

Great way to begin it.

If you are ever out east, be sure to drop by the Golden Age Air Museum. We love to hear about and help where we can, with new projects.

Keep posting your progress !
Mike

[regular122]

Opinions needed.

I have been playing around with the limitations of space and the design of the Replica Plans cockpit size and instrument panel. The good news is, at 87.5% from the original, we are only talking an inch here and an inch there.

The challenge for me is to develop a safe and effective instrument panel that will also look like the original. There have been a great many interpretations of how to do it for the Currie Wot based design. The first pic shows an SE5a actual cockpit at TVAL (photo credit to thevintageaviator.co.nz). Two of the really nice Replica Plans cockpits are below on Jack Dean and Bill McLearran's machines.

Still, the oval shape of the cockpit with the metal stiffener and instruments on the resulting shelf I have yet to see duplicated (although Bill makes an excellent attempt at the curvature). I think it could be done like the original and also the original spaces and instruments may be modified or mocked up to allow for the radios, artificial horizon, etc.

I put together a quick concept sketch that would make slight adjustment to the Replica plans squared cockpit space and give it the oval shape. I also think the fairing on the Replica Plans design can be tapered with a radius more like the original which would also allow that inch or so that is needed.

In thinking of what to do with the Lewis Drum shelf, rather than leave it out, I think a false drum cover could be made in the box and use the handy box to hold the radios.

In my concept sketch, it seems to me I could convert the Air Pressure Control Switch into a traditional ignition switch with L/R Magnetos. It has the right look and shape but would need to be fabricated. The dolly switches, which would be behind the Altimeter on a side panel, could be used for the Master and Alt Battery switches.

The Fuel Selector could be made into that instrument for the main and wing tanks. The clock, temp, compass, tach, airspeed indicator and altimeter could all keep there locations and design.

The Air Pressure gauge might be converted to something else, like a vertical speed indicator or artificial horizon or something.

As to the inclinometer, I have no experience with making coordinated turns on such an old instrument. For those with experience flying WWI replicas, I would think a turn indicator with ball would still be needed? Would need to solve that.

The dead space to the left of above the Lewis Drum box is open panel for the Vickers and loading feed access.

The Fuel Pressure hand pump would be a mock up unless I can think of what to use that for.

I would welcome your opinions and your experience. Thanks, Steve

[Dart]

The ball is the most important instrument on your panel.

When it is in a smile, ends up, step on the ball. If it's a frown, step away from it.

IMHO, every other instrument, with the possible exception of the oil temp gauge, is just overkill.

The ball is the only thing I look at regularly. I glance at the oil temp now and then just for fun. I don't know about the SE5a, but my Nieuport can fool one into cross control by feel.

The rest - airspeed, altitude, RPM, etc., are easily determined by sight and sound.

If there's an oil leak that will cause a drop in pressure, you'll know it by smell and taste.

[regular122]

The ball is the most important instrument on your panel.

When it is in a smile, ends up, step on the ball. If it's a frown, step away from it.

IMHO, every other instrument, with the possible exception of the oil temp gauge, is just overkill.

The ball is the only thing I look at regularly. I glance at the oil temp now and then just for fun. I don't know about the SE5a, but my Nieuport can fool one into cross control by feel.

The rest - airspeed, altitude, RPM, etc., are easily determined by sight and sound.

If there's an oil leak that will cause a drop in pressure, you'll know it by smell and taste.

So I take it by these remarks that the original bubble type inclinometers in a frown shape would be less much less than what would be needed?

[Dart]

It's just a different way of doing the same thing.

Bubble in a frown or ball in a smile has the same purpose.*

The big thing is the size. Today's bog standard slip indicator is small, as most GA aircraft are very stable, and folks aren't doing big slips in C172's.

The bubble type are typically pretty large, and so they're not only more responsive (having a larger throw), but markings for how much are easy.

The KC Dawn Patrol guys have it just right:

http://www.dawnpatrol.org/questions.htm (scroll down the page)

* Terms for things in, on, or done by Aircraft aren't my thing. The seat and the stick and stuff are in the hole at the top of the body of the airplane as far as I know.

[Brad]

It's just a different way of doing the same thing.

Bubble in a frown or ball in a smile has the same purpose.*

The big thing is the size. Today's bog standard slip indicator is small, as most GA aircraft are very stable, and folks aren't doing big slips in C172's.

The bubble type are typically pretty large, and so they're not only more responsive (having a larger throw), but markings for how much are easy.

The KC Dawn Patrol guys have it just right:

http://www.dawnpatrol.org/questions.htm (scroll down the page)

* Terms for things in, on, or done by Aircraft aren't my thing. The seat and the stick and stuff are in the hole at the top of the body of the airplane as far as I know.

That almost sounds like a challenge... or a dare. :p

And C172's aren't much fun to fly.

[regular122]

I've been working a little on the layout of the project. Even though I have 3 sets of original Replica Plans SE5a sets of plans and a working set beyond that, I wanted to digitize the plans for ready reference, notes, etc. Now that I have that done, I can tinker around while traveling.

Since the project already has a lot of work done, I am organizing the work to what makes best sense. While the wood fabrication done to date is superb, there are some good fittings, some so so fittings and some fittings I don't think I want to use.

In organizing, I have decided to use the FAA Amateur-Built Fabrication and Assembly checklist as my job plan. It will be the points checklist for it later anyway. Might as well organize the work along those lines and match the requirements with the Gogi drawings.

The first drawing of the plans deals with the aircraft overview. The next two drawings deal with the empennage. So I sorted through a big box of metal fabricated fittings to see what is there, what cannot be used and what needs to be fabricated.

Drawing Sheet #2 - Stabilizer and Elevator. The structure itself with regard to the woodwork only needs the balsa filler blocks. Everything else appears to be sound and well-crafted. I will need to fabricate some brace wire fittings, doubler plates and a leading edge cover for the stab. I am debating whether to make the leading edge out of wood instead of aluminum as per plans.

Drawing Sheet #3 - Fin and Rudder - The lower portions of the rudder will need to have mahogany ply inserts and boxing for the lower rudder for reinforcement. The spars of fin and rudder will need some fill as well. Brace wire brackets, incidence shims, tail wheel steering assembly, and a rudder horn doubler plate will have to be fabricated. A leading edge cover also needs to be made and same goes as to whether to make this from wood or from aluminum as per plans. Once assembled and covered, I will need to make stab and fin leading edge fairings as well.

I've attached some pics of the assemblies laid out on the floor but not assembled. I would also welcome any thoughts on the leading edges being wood or aluminum or any comments in general. Steve

[regular122]

Got my Elgin Cockpit pocket watch back from repair. Ticking away now. And I was happy to come across a Mark VB Altimeter, one that matches a mid-summer 1918 SE5a better. It works but will need some restoration. The other item is a Schrader Universal tire pressure gauge from WWI. Gotta keep those tires inflated properly. Lots more instruments and bits to acquire as well as current instruments to make period looking. Steve

[regular122]

Have been able to get through alot of the blueprints to verify work. Have a pretty good idea now what remains to be fabricated. I also found a very nice Zenith Mark V altimeter.

I decided to go ahead and finish the Lewis. I hate to leave anything half finished. You can see how I made the 90% plans for it HERE (http://www.theaerodrome.com/forum/showthread.php?t=66903). The barrel, gas tube, trigger housing and recoil spring housing are not attached yet. That is why it is upside down. But you get the idea.

I can make some good progress in the rare little snatches of time I can get, if I can get it. Steve

[regular122]

Got to work a little more on the plane today. Lewis is coming along nicely. I am now working up the housing and jacket from a cut up soup can and 2" PVC pipe.

In between gluing and drying the Lewis, I was able to make a preliminary template for the instrument panel. The Gogi plans have a very rudimentary panel with very little detail (see pic). The panel I worked up is scaled from full scale Kiger plans, then converted to .875 and then adjusted to the Gogi plans.

The template now accounts for the instrumentation and locates them very closely to the original layout, except for the VSI in lieu of the Air Pressure Gauge. Some instruments will need to be added in other locations and I intend to place the altimeter and watch on the cockpit reinforcement shelf as per original.

[smokeyshra]

I'm building a replica plans Se5a also. Have been down to Ryan field to visit the guys you got your project from and correspond with them. PM me and perhaps we can share hints and encourage each other. I am building from Replica Plans but also have Replicraft which I am using to make modifications for more realistic detail. Also have a FaceBook group with a couple builders contributing.
-Smokey

[kdahlhaus]

I'm building a replica plans Se5a also. Have been down to Ryan field to visit the guys you got your project from and correspond with them. PM me and perhaps we can share hints and encourage each other. I am building from Replica Plans but also have Replicraft which I am using to make modifications for more realistic detail. Also have a FaceBook group with a couple builders contributing.
-Smokey

What is the Facebook group? I'd love to tag along.

[smokeyshra]

It is called "Replica Plans Se5a Builders Group" Hope to see you.

Smokey

[regular122]

It is called "Replica Plans Se5a Builders Group" Hope to see you.

Smokey

Sent you a join request. In the mean time, I hope to make steady progress here! I have been getting some good support and photos from some folks here on this forum on the wing mods to accommodate four ailerons vice two. Steve

[kdahlhaus]

Thanks, found the group and request sent.

https://www.facebook.com/groups/1884302241792407/

[Griffo]

Hi Regular 122.
I'm new here but we've just put the only flying replica SE5A in the air in Australia. We purchased a complete aircraft from the Netherlands in 2015 and began the process of refurbishing it to (as close as we could afford) D6995 'Y' of 2 Squadron Australian Flying Corps definition as it was in 1918. One of the major jobs was to 'recreate' the cockpit. What we have now is as close as our budget allows, and we still have some cosmetic detail to go. Ill try to post some photos of the 'transition' - it was a lot of work. Best regards. Griffo

[Griffo]

Hi Regular 122
To get a Certificate of Airworthiness for our machine we had to fit 3 modern and serviceable instruments - Airspeed, Altimeter, and G Meter. We didn't want these on our main instrument panel, so we mounted these in the 'Box' for the Lewis spare mag. For flight the modified mag is removed and the instruments exposed. On the ground and on display, the Lewis mag covers the modern instruments. I think you were going to do something similar with your radios. Cheers

[regular122]

Great stuff Griffo. That is along the same lines as the instrumentation experiments that I am doing as well. Nice to see the false drum cover on the instruments and yes, I am thinking to cover the radios this way.

I will lay out the instruments as shown in the previous template for the panel. Love the cockpit stiffener you guys built. It just doesn't look like an SE5a without it.

I am curious, did you make the aileron mods to the upper wings or was this done earlier? Also, did you find that you needed to extend the upper dimension of the cowl / panel? The Currie Wot plans are about 2" too shy and make the cowl a little slimmer in profile.

Another question. Is this a Currie Wot based design? Is it a Replica Plans? Noticed some metal tubing in the cockpit pics and was curious.

Awesome plane. Thanks for sharing with us! Steve

[Griffo]

Hi Steve. Well we have a bit of a mystery here. We don't know what plans were used............ and we are trying to find out !!?? The builders plate lists Albert H Braun of Swansea Illinois as the builder. Unfortunately Albert lost his medical some time after the build (1996) and he put the machine on the market. I think he only flew about 40 hours in it before losing his medical. As far as I know, he then sold the machine to a couple of guys in the Netherlands. For whatever reason they did very little flying in the machine and we tracked it down because it pretty much matched the general build spec we were thinking of. I found Alberts original advert for sale. Albert unfortunately died in 2008. I've been in touch with Jim at Replicraft and he says it's definitely not one of his. Thanks for the tip on Curry Wot - I'll chase that up. I think Albert was a member of EAA Chapter 64 and I've emailed the president there, but no answer yet. I'll keep you posted. Best regards. Griffo

[regular122]

Griffo,

The Currie Wot was a 1930s aerobatic biplane design that saw some popularity in the 1930s (pic1). During the late 1960s, Slingsby Sailplanes took the design, modified it and produced 6 x scale SE5as for the movie Darling Lili. The planes have appeared in a dozen popular war films such as Richthofen and Brown, Zeppelin, etc (pics 2-3).

C.R. Goguillot, aka 'Gogi,' refined the design from Currie Wot plans and produced the Replica Plans SE5a. He began making the plans sets available to the public in the early 1970s. Most of the flying SE5s today are some variation of the Currie Wot design. They are roughly 90% scale and to the eye appear quite authentic as their span and length are matter of 6+ - inches each end difference. They can typically be spotted by the single long ailerons on the lower wing only. Others have had their wings modified to have four ailerons.

The N Number on the one you have when it was built in the states should be traceable and may very well tell upon what the experimental aircraft was based.

I have attached Gogi's old card (pic 4). He died more than a decade ago I believe, and Replica Plans is no longer. The plans sets, which are quite hard to come by, are each serial numbered to correspond with one completed aircraft (pic 5 for first sheet). I do not know of anyone making new authorized plans sets. There are however many more plans out there than planes. Steve

[regular122]

By way of update, I managed to get a couple of hours to work on the 90% Lewis. Travels are taking all of my time. But it is coming along nicely. Fabricated the jacket from a PVC pipe and a cut down soup can and installed the trigger. The jacket slips over the barrel assembly. Steve

[Griffo]

Hi Reg 122

So far I've managed to eliminate RepliCraft, Airdrome and Currie Wot plans !! She had the 4 aileron config from Day 1 , and our front cowls haven't been touched - they are the same height and shape as the original. I believe the original builder (Albert Braun) may have been a member of EAA Chapter 64 from Illinois. I've emailed the president there to see if anyone associated with the build is still around - haven't heard back yet. I have a copy set of original plans from the Royal Aircraft Factory and all the significant dimensions are as per the original except that the airfoil section of the wings has slightly more camber top and bottom. We still have some cosmetic detail to go. The mystery continues ..... Best regards

[regular122]

Bit by bit in the time I get. Latest look of the Lewis. Countersunk bore, reverse thread muzzle with metal nut. Removable shroud like original, locked down with wooden gas key. Gun is mostly poplar with a few screws and a modified AK trigger fixed into the wood. Outside details taking shape per blueprints.

[Major Larabee]

Griffo,

The Currie Wot was a 1930s aerobatic biplane design that saw some popularity in the 1930s (pic1). During the late 1960s, Slingsby Sailplanes took the design, modified it and produced 6 x scale SE5as for the movie Darling Lili. The planes have appeared in a dozen popular war films such as Richthofen and Brown, Zeppelin, etc (pics 2-3).

C.R. Goguillot, aka 'Gogi,' refined the design from Currie Wot plans and produced the Replica Plans SE5a. He began making the plans sets available to the public in the early 1970s. Most of the flying SE5s today are some variation of the Currie Wot design. They are roughly 90% scale and to the eye appear quite authentic as their span and length are matter of 6+ - inches each end difference. They can typically be spotted by the single long ailerons on the lower wing only. Others have had their wings modified to have four ailerons

The N Number on the one you have when it was built in the states should be traceable and may very well tell upon what the experimental aircraft was based.

I have attached Gogi's old card (pic 4). He died more than a decade ago I believe, and Replica Plans is no longer. The plans sets, which are quite hard to come by, are each serial numbered to correspond with one completed aircraft (pic 5 for first sheet). I do not know of anyone making new authorized plans sets. There are however many more plans out there than planes. Steve


The Slinsby built A/C although based on the Currie Wot plans are completely different A/c and are vastly different from the Replica Plans examples.
One of the original Six is currently being rebuilt in the UK to fly once more.

[regular122]

The Slinsby built A/C although based on the Currie Wot plans are completely different A/c and are vastly different from the Replica Plans examples.
One of the original Six is currently being rebuilt in the UK to fly once more.

Thanks for that picture. Definitely shows the wing structure differences. And kudos on the restoration. Are any of the Slingsby plans still out there? Steve

[Major Larabee]

Thanks for that picture. Definitely shows the wing structure differences. And kudos on the restoration. Are any of the Slingsby plans still out there? Steve

Sadly no plans are available for the Slingsby built SE5's. What ever were done were lost in a fire at The Slingsby Factory.
We have found some paperwork relating to stress calls etc. Compared to the Currie Wot and the Replica plans SE5 the wings are almost a foot wider cord making them a better and more accurate shape.
The fuselage is Much bigger and the aeroplane is generally bigger and beefier !!

[regular122]

In covering the differences between the original plan dimensions of the SE5a and the Replica Plans blueprints, it would seem that several minor modifications can be made to restore the shape and the look of the aircraft to greater accuracy. What follows is a discussion on what I believe I can do to make modifications to existing work. Any advice or precautions are welcome.

Several Replica Plans builders / owners have modified their ailerons from the extra long lower wing types to the matching shorter types on both top and bottom wings. The first picture is a concept mark up on the lower wing plans. The second pic is the upper wing mark up where the ailerons would need to be added.

The third picture shows the fuselage differences. One of the criticisms of the appearance of the Currie Wot based SE5a replicas is the narrower shape of the nose and the lower profile of the cockpit area. Raised plywood top decking and cockpit carlins would give it the correct appearance. Additionally, a second set of stringers running from the cockpit to about halfway down the cockpit better replicate the SE5a's distinctive look. The footstep should also be on the interior side of the cockpit's rear bulkhead.

The last picture shows how the instrument panel would need to be enlarged to fit the more accurate cockpit carlins. Steve

[regular122]

Found some suitable dolly switches for the cockpit. Nice air ministry marks. Lewis is ready for drum construction and have rounded up the materials for that. Steve

[cavelamb]

Hi Steve (et al),

I love the SE-5A. I must have built 5 or 6 balsa models of them when I was a kid. I had my own squadron.

I'm here because an old project re-emerged from the past - Siminolewind's replica SE5. He's having landing gear problems. Seem authentic. :)
I'm the guy who drew it.

Thought I'd offer the drawings from that one to see if they might help you get your project started.

I tried hard not to distort the shape. Or at least distort it as little as possible.
If someone is going to put all that time, money, and work into a project, it should look like what it's supposed to be.
I want it to be worth while in the end.

My drawings aren't dimensioned because they are drawn full scale. Full PROJECT scale. If you want I can probable dig up the original files.
I draw with Design CAD. Back then it was the DOS version (really).
But if I can find the files, the 3D version should be able to read them.
I can offer DXF files, if that would help.
Or print to PDF with a scale ruler on the drawing.

In the mean time, here's a low res picture of the fuselage file.

Richard
http://www.home.earthlink.net/~cave-1/images/se5-44.PNG

[regular122]

Thanks Richard and welcome to tbe forum by the way. I have found the folks here to be overwhelmingly helpful in both aircraft projects and historical research. I sent you a PM. I have the full scale Kiger plans and a some digital copies of a few original drawings. I also have about three sets of the Replica Plans drawings. It is always good to have as many points of reference for how people solve problems. Thanks for letting me know about it. Steve

[cavelamb]

Thanks Richard and welcome to tbe forum by the way. I have found the folks here to be overwhelmingly helpful in both aircraft projects and historical research. I sent you a PM. I have the full scale Kiger plans and a some digital copies of a few original drawings. I also have about three sets of the Replica Plans drawings. It is always good to have as many points of reference for how people solve problems. Thanks for letting me know about it. Steve

Those guys are way better than my sketches.

These are the only drawings I could find of that project.
Actually, there weren't many others. A few hand sketches of tailwheel detail,
and things like that. Chuck had his own ways of doing things...

I sent you a couple of PDF prints.
Probably ought to post them on my web site too...

These may not be in the same scale. I think the fuselage is in 1/12 and the wing is in 1/10. But they both have scale rulers on them. If that's a hassle let me know and I'll see if I can fix it.
Note Kinkos and a calculator can do miracles.

Have fun...

http://www.home.earthlink.net/~cave-1/images/C-Print-SE5-44%20Fuselage.pdf

http://www.home.earthlink.net/~cave-1/images/B-Print-SE5-44%20Wing.pdf

[smokeyshra]

Steve (or anyone else who knows),

MTGunner and I are building also and have just come across something that has us scratching our heads. The wing spars per the plans are; Main 3/4 x 4, Rear, 3/4 x 2 3/8. The center section spars are 4 3/8 x 7/8 and 2 7/8 x 7/8. The problem is with the center section ribs. The plans call for using the same shear webs as the wing ribs. Unfortunately they can't accommodate the additional depth. Have you noticed this yet. Also, there is a discrepancy in the plans regarding wing attach point double thickness. We decided easily fixed with thicker doubler.

Smokey

[cavelamb]

Back @ Seminolewind...

Can you get a camera (or phone) in there and photograph a few of the joints?
Chuck always used a two-rivet-per-joint arrangement.

I ask because, while this is not the SE5A project I was involved in, the airframe might could possibly be a Chuckbird after all - one that someone dressed up a bit?

[regular122]

Steve (or anyone else who knows),

MTGunner and I are building also and have just come across something that has us scratching our heads. The wing spars per the plans are; Main 3/4 x 4, Rear, 3/4 x 2 3/8. The center section spars are 4 3/8 x 7/8 and 2 7/8 x 7/8. The problem is with the center section ribs. The plans call for using the same shear webs as the wing ribs. Unfortunately they can't accommodate the additional depth. Have you noticed this yet. Also, there is a discrepancy in the plans regarding wing attach point double thickness. We decided easily fixed with thicker doubler.

Smokey

Smokey,

Let me take some measurements of my wing spars and look at the center section when I get back from travels. Steve

[regular122]

Smokey,

Regarding the question you asked, I took a look at the top wing main and rear spars and also the center section. You had mentioned that the rear spar for the top wing was 3/4" x 2 3/8" but my plan sheet number 1170 Sheet 1, dated 16 June 1971 shows that the dimension is 3/4" x 2 5/8". See 1st pic.

The Top Wing rear spar measured 3/4" x 2 41/64" See 2d and 3d pic
The Top Wing front spar measured 3/4" x 4 1/16" See 4th and 5th pic

More pics in next post.

[regular122]

Continued...

I also tried to measure the spars of the center section although it is covered. I removed the auxiliary gas tank and could get approximate measurements of the spar breadth but not width due to being covered in fabric. As to fittings, the center section is slightly wider on the spars than the wing for overlap. I don't know if any of this helps or not. I also am attaching a pic of Bill McClearen's center section as it joins the top wing and a pic of the plane overall to show how the top planes are attached. A gap is normal. Steve

[smokeyshra]

Thanks Steve, very helpful, especially the pics. My 3/8 measurement was a typo. I think I have it figured out now. Just building the last 4 aileron ribs now. I will have 4 ailerons so the trailing edge of these 4 are filled with 1/2 spruce and skinned with 1/16 ply to provide mounting for the slave struts. These are the last of the wing ribs. Will begin the center section when these are done.
-Smokey

[regular122]

Smokey,

I should point out that Bill McClearan's plane has an increased center section (about six inches each side, most of which is an expanded aux fuel tank) and he removed six inches of spar per wing where they join the center section and replaced the fittings on a new rib, etc. The result posted in the above pic of the SE5a from the rear, is a dimensionally correct SE5a appearance without departing from the overall dimensions of the Replica Plans dimensions. You can see the result of these mods here before they recovered it and how it looks once attached and covered.

The pics I showed you of my plane are prior to these modifications and are per the standard plans designs with the center section more square and without fairings (which would still be on the wings on the original plans rather than moved to the new center section). Steve

[regular122]

Have not posted in a while but here is some of the latest work done.

I have been able to work the technical dimensions of the drums while trying to keep them faithful to the Lewis and be able to have a tight fit that will also lock down. I used the 1:1 scale vacuum-formed ABS shells from foxflier.com, as their 7/8ths version was in reality a 60% vice 85-90% scale. A simple height cut down and an adjustment on the metal shroud housing did the trick to merge the scale and the correct looking drum.

I used some of the internal drum support ideas from the foxflier.com website but made my own support adjustments for even greater strength. I like the results.

Continued next post...

[regular122]

I was able to work the center post locking mechanism similar to the actual Lewis by incorporating the receiver post into the drum lock design. The drums still need foam fill and leather handles and then they are done. The Lewis then needs final detailing and paint.

The entire Lewis exercise has been beneficial. It has more than shaken out my previously unexplored woodworking skills and allowed me to round up my tooling, work from blueprints, etc. It also has been a great exercise in doing a little at a time until something gets completed. Steve

[regular122]

Another bump. In the interim, I've been trying to learn tail wheel skills and finally finished out the Lewis. Had to work out some solutions for the handles for the drums. Everything is nice and tight--hopefully to withstand 125mph winds. The gun will need some final detailing and weathering to make it look real and I need to make the leather drum handles but I like how it ended up. The camera fish eyes a bit but the gun and shroud are actually straight!

Will have some good news soon on the SE5a projects. Steve

[Dart]

Very cool.

[regular122]

Managed to get the finishing touches done on the Lewis. After sanding down the base black enamel coat, I then used a spray can of Bronze metallic black purchased from the aircraft department of Home Depot. Once that was set and dried, I then used a cotton rag with a thin wash of silver enamel and thinner to give the wear and highlights to the gun and the drum. It came out as I had hoped. Very pleased with the Lewis overall. Enjoy, Steve

[Minimaxinvasion]

Looks like you have a great SE5A project there. I am UK based and I am looking to build one. I see from earlier in this post you have three sets of Replica Plans drawings. I wonder if you would you be willing to sell me a set. These are approved in the UK by the LAA but are very hard to come by over here. Unless I can find a set of these drawings I am not going to be able to build one. Many Thanks Alan

[ONEALM]

Well done Steve ! The metallic effect is very convincing.

[regular122]

Well done Steve ! The metallic effect is very convincing.

Thanks! It is probably illegal in California because of how scary it looks. I've made three drums for it as well that all can lock on to it. Now I might need to make a half drum to cover radios as discussed earlier in the threads.

And to Alan, I sent you a PM. Steve

[FlyBro]

Steel Tube (4130) Fusrlage ?
CldLk-Tim

[regular122]

Steel Tube (4130) Fuselage ?
CldLk-Tim

Spruce and Mahogany ply mostly. Steve

[regular122]

Need some of the engineering experts out there. I want to make the landing gear on SE5a No.1 look like the original. My thinking is to either add light wooden ash sleeves to the existing gear legs or go the other direction and make new gear legs from ash like the mid-production originals. Daniel Ryfa's beautiful SE5a (last pic) has the modified wooden legs. Mine has the blueprint metal legs.

I also want to make the light airfoil on the axle supports like the original. What would be some ways to do this without upsetting strength and what W&B issues should I look out for? Steve