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18

Stage 2: Building the Fuselage

The fuselage of the Dr.1 was made of welded steel tubing, braced with cables.  The model
simulates this construction with a combination of zinc castings, brass rods and thread bracing.
Zinc is used as it is stiffer than Britannia.  The best way to fasten zinc to itself or brass is with
epoxy, not cyanoacrylate.   To make the assembly easy, combinations of welded tubes in the
original have been combined into cast sub-assemblies.  The entire fuselage is constructed in a
jig to ensure alignment.

A.

The Construction Jig

As shown in Figure 2.1 and on Sheet E, assemble the construction jig from the Side Panels
(FW4) and Supports 5

– 10 (FW5-10). Use minimal glue to hold the pieces together as you may

want to remove frames later for working on details. You may want to glue the bottoms of the jig
sides (FW4) to a work board for stability. Do not glue in FW10 as it needs to be removable to
get the fuselage out of the jig.

Part #

Name

Count

Material

FW4

Fuselage jig side

2

Laser cut ply

FW5

Fuselage jig 5

1

Laser cut ply

FW6

Fuselage jig 6

1

Laser cut ply

FW7

Fuselage jig 7

1

Laser cut ply

FW8

Fuselage jig 8

1

Laser cut ply

FW9

Fuselage jig 9

1

Laser cut ply

FW10

Fuselage jig 10

1

Laser cut ply

WP9915

Posts

12

1/8” dia x .75 brass tubing

Insert the precut posts in side panels and support members so they are centered. Do not glue
these in place.

Figure 2.1 Fuselage Construction Jig

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Содержание MA1040

Страница 1: ...1 Tri Plane Instruction Manual Prototype by Dr David G Ullman 2013 Manufactured by Model Shipways Inc dba Model Expo Hollywood Florida Sold by Model Expo a division of Model Shipways Inc http www modelexpo online com Model Airways Kit No MA1040 ...

Страница 2: ...2 ...

Страница 3: ... 1 Main spar 9 2 Wing ribs 9 3 Wing Tips 10 4 Leading Edge 10 5 Final wing details 11 B The Middle Wing 13 C The Top Wing 14 1 Top Wing Basic Structure 15 2 Ailerons 16 3 Aileron pulleys 17 Stage 2 Building the Fuselage 18 A The Construction Jig 18 B The Basic Fuselage 19 1 Preparing the cast parts 19 2 Preparing the Frames 19 3 Assemble the engine mount 20 4 Assemble the front of the fuselage 21 ...

Страница 4: ...ontrols to the Engine 36 A Engine connections and installation 37 B Spent Ammo Can 38 C Control yoke 38 D Ammo can and Tachometer 39 E Magnetos 39 F Fuel air management 40 G Seat 40 H Final Cockpit Details 41 Stage 7 Final Assembly of the Model 41 A Spandau Machine Guns 41 B Installing the lower and middle wings 42 C Wing Struts 42 D Adding the Landing Gear 43 E Finishing the Fuselage 43 1 Turtle ...

Страница 5: ... 1s nor are there a complete set of drawings The Dr 1 was small airplane 18 11 5 77m long with a span of only 23 7 7 19m Its empty weight was a mere 895lb 405 kg It was powered by many engines primarily the Oberursel UR II engine which was a copy of the French LeRhone type 9Ja This was a rotary with 9 cylinders that spun around the stationary crankshaft producing 110 hp 84kw What made the Dr 1 suc...

Страница 6: ...de view and top view of the model with sections through the front of the fuselage Sheet B Front view and fuselage details Sheet C Wing Layouts Sheet D Layout of tail surfaces ailerons and landing gear and various other details Sheet E Engine Details Some general suggestions Copy the wing and other surface layouts if you want to preserve the original Sheets Cut tubing by rolling it under a blade it...

Страница 7: ...ps of wood with 220 or extra fine sandpaper prior to using D Glue Glue wood parts with cyanoacrylate super glue To apply put some drops on a paper pad and use toothpicks to apply to the model When the material on the pad gets stiff or hardens tear off top layer of pad and work from fresh sheet Best is to use epoxy for metal parts Liquid Nails Metal Projects LN 203 or other 5 minute epoxy is best M...

Страница 8: ... 32 laser cut plywood WW2 Bottom wing spar front 2 1 32 laser cut plywood WW3 Bottom wing spar rear 2 1 32 laser cut plywood WW4 Wing rib 16 1 32 laser cut plywood WW5 Bottom mid tip rib 2 1 32 laser cut plywood WW6 Bottom mid tip rib doublers 2 1 32 laser cut plywood WW7 Bottom mid wing tip 2 1 32 laser cut plywood WW8 Bottom wing leading edge 2 1 64 laser cut plywood WW9 Spar connector 2 1 32 la...

Страница 9: ...ottom making sure the slots are aligned See Figure 1 2 The rear spar notches are offset for the root rib so it is canted out at the bottom to clear the landing gear strut Glue on the top Mark inside the spar to note the root relative to the tip Check that the ribs fit in the slots and that the root rib is canted outward at the bottom Figure 1 2 Bottom Wing Spar Details 2 Wing ribs There are eight ...

Страница 10: ...1 8 inch 8 x 3 mm stock as shown Figure 1 6 Wing Tip Details 4 Leading Edge The leading edge WW8 is made from 1 64 inch 4mm laser cut plywood The actual Dr1 had a warped plywood leading edge as is used here To prepare each leading edge six in all for the three wings first make a jig from the supplied piece 1 4 x 3 4 inch 6 x 18mm basswood a 3 16 inch 5mm rod and some scrap 1 64 inch 4mm material G...

Страница 11: ...out 1 32 of an inch 8 mm Be sure each rib aligns with the Vee notches as shown Best to start gluing at the two ends and once you are sure of the alignment glue all the other leading edge tabs to the spar Then glue the bottom of the leading edge to the ribs being sure the leading edge is pulled tight against them Clothes pins help here Best to start gluing at the middle ribs and work outward While ...

Страница 12: ...e of the root and tip ribs 5 f First finish Finish the wing with a couple of thin coats of clear semi gloss or matte spray before doing the next steps 5 g Lower leading edge bracing On the original Dr1 the lower lip of the leading edge is tied to the spar with pieces of tape woven material much like a wide ribbon On this model 1 16 inch ribbon is used Cut pieces of ribbon to 3 8 inch 10 mm long or...

Страница 13: ...W4 Wing rib 14 1 32 laser cut plywood WW13 Middle root rib 2 1 32 laser cut plywood WW5 Bottom middle tip rib 2 1 32 laser cut plywood WW6 Bottom middle tip rib doubler 2 1 32 laser cut plywood WW7 Bottom middle wing tip 2 1 32 laser cut plywood WW9 Spar connecter 2 1 32 laser cut plywood WW14 Middle wing leading edge 2 1 64 laser cut plywood WW15 Middle wing root trailing edge 2 1 32 laser cut pl...

Страница 14: ... clear the Top Wing Strut Figure 1 12 The inboard notch in the trailing edge WW15 is glued to the root and first rib as in Figure 1 13 This notch was to allow the pilot to see forward below the nose essential in a dog fight Be sure to make a left and right leading edge WW13 Figure 1 13 Middle Wing Root Detail C The Top Wing The Top Wing is similar to the other wings but has ailerons Top Wing Parts...

Страница 15: ...to build a left and right spar On each half the 4 inner most ribs WW4 are the same as on the other wings The 6 outer ribs WW19 and the tip ribs WW20 22 are shortened to leave room for the ailerons as shown in Figure 1 14 The top wing leading edge is WW23 The Aileron Spar is made from 3 32 x 1 4 inch 2 4 x 6mm stock carved as shown Sheet D Easy way to carve this is to wrap fine sandpaper around a 6...

Страница 16: ... Cast Britannia WP160K Pulley axels stock 1 32 8mm rod The ailerons are shown in Figure 1 16 painted and on Sheet D to scale Begin with the front spar It is made from a 1 8 3mm brass tube 6 152mm long Using a hammer and file flatten the outer end as shown until it is flat at the tip Figure 1 16 Completed Aileron Bend the Aileron Rear Spar 1 32 8mm brass rod to shape as shown on the Sheet D With bo...

Страница 17: ...ich is the same on both sides and the left WP10 inner body as folded WP11 is essentially the same as WP10 but folded as a mirror image Put two pulleys in the outer body and one pulley in each locations on the inner body Glue these in place on the top wing at the locations shown on Sheet C and being sure that they are equidistant from the top and bottom of the spar so that the cables can pass aroun...

Страница 18: ...ruction jig from the Side Panels FW4 and Supports 5 10 FW5 10 Use minimal glue to hold the pieces together as you may want to remove frames later for working on details You may want to glue the bottoms of the jig sides FW4 to a work board for stability Do not glue in FW10 as it needs to be removable to get the fuselage out of the jig Part Name Count Material FW4 Fuselage jig side 2 Laser cut ply F...

Страница 19: ...r the holes for the landing gear attachment Use two pairs of pliers and if the casting breaks just epoxy in place to clear the landing gear struts File the posts on the front of FC1 as needed so they slip into the engine mount sockets FC2a 2 Preparing the Frames For each of Frames 5 9 FW5 9 add the cross bracing and turnbuckles FC 20 as shown in Figures 2 2 and 2 3 The model is like the original w...

Страница 20: ...e 2 4 using the rigging thread This is best done in two halves starting at the center bottom and meeting at the top Then adjust the tension in the threads until the panel is centered Glue the ends of the threads together Figure 2 4 Frame 5 with Cockpit Rear Wall 3 Assemble the engine mount The engine mount is made from two parts FC2a and FC2b shown aligned in Figure 2 5 These are epoxied together ...

Страница 21: ...ls FC1 in the Engine Mount as shown in Figure 2 6 Add Frame 3a FC3a to stabilize this structure as seen in Figure 2 7 The sockets for the Top Wing Strut are forward Do not install FC4a at this time Make sure the sockets for the Top Wing Strut FC32 are forward as shown in Figure 2 7 You can use the Strut to ensure the spacing of FC3a Use minimal glue here as this frame may need adjusting in final a...

Страница 22: ...uble cross bar Be sure it is on top Secure each frame with rubber bands as shown in Figure 2 7 Put the fore fuselage in the jig as shown in Figure 2 7 It is easiest if the brass tubes are pushed out of the way outboard and then pushed back halfway as the fuselage is positioned as shown in Figure 2 8 Once in place secure with rubber bands Figure 2 7 Fuselage in the jig Figure 2 8 FC1 in the jig Sig...

Страница 23: ...OK and excess is easy to trim Aluminum paint will hide the epoxy color When the epoxy has set then epoxy to frames FC7 and FC8 Frame FC8 the forth one from the left in Figure 2 2 is different from the others The holes in the frame are for FM3 NOT FM1 FM1 fits on the shoulder of FC8 just like the others Figure 2 9 Top stringers in place Next install the FM2 stringers along the bottom of the fuselag...

Страница 24: ...crap in place of the lower wing and the fuselage can rest on it and the end and then can be turned to any orientation to work on Figure 2 10 Final Assembly Jig 8 Installing the controls Part Name Count Material FC27a Control column 1 Cast Britannia FC27b Control column 1 Cast Britannia FC28 Rudder pedals 1 Cast Britannia FC 29 Stick yoke 1 Cast Britannia FC30 Aileron actuation shaft 1 Cast Britann...

Страница 25: ...controls Make the Fuselage Control Brace FM5 from 1 16 1 6 mm brass rod as shown on Sheet D Assemble it with the rudder pedals FC28 no glue and glue into FC3b Attach rudder control lines turnbuckles FC20 Each turnbuckle has 1 5 3 7cm of cable to the rudder pedals and has a 12 30cm to later be attached to the rudder For now wrap this 12 line around a notched scrap wood as shown in Figure 2 11 Figur...

Страница 26: ... attached to the elevators Insert FC30 in FC4b and glue on the FM4 assembly being sure that the aileron control is symmetrically aligned with the stick and that the assembly can rotate in FC4b Figure 2 12 Aileron Elevator Control Sub Assembly Glue the rudder control sub assembly into the fuselage followed by the aileron elevator control sub assembly Glue the floor boards FW1 to FC3b FC4b and FC4d ...

Страница 27: ...id to it The forward part of the skid is supported by a piece of bungee cord to give some suspension Loop a short length of rubber beading LO2 through the upper tail skid bracket and tie with simple knot to frame FC9 as shown in Figure 2 14 Soak with thin cyanoacrylate and trim excess elastic cord Figure 2 14 Tail Skid Stage 3 Building the Tail Surfaces The tail surfaces on the original Dr 1 were ...

Страница 28: ...omplete the stabilizer by adding root ribs TP1 root fore ribs TP2 tip ribs TP5 Take care as TP2 and TP5 are nearly the same length Cut leading edges TM1 from 1 16 1 6 mm brass rod and glue in place Figure 3 1 shows the elevator before cleaning up excess epoxy and finishing Make the elevator hinge block TS1 by cutting groves in the opposite sides of 3 32 2 4mm stock to fit the trailing edge of the ...

Страница 29: ...ed to the stabilizer with three bands of copper tape 1 8 wide by 1 long 3 2 x 38 mm wrapped around the elevator and stabilizer structure two times for strength The copper tape comes wide Slice it down the middle The stabilizer is glued to the fuselage as shown on Sheet A at Frame 8 and the Rear Post The original was bolted at these locations Add the stabilizer brace TS2 shown in Figure 3 3 from le...

Страница 30: ...elevator and shown in Figure 3 4 Figure 3 4 Rudder mounted to Fuselage D Connecting the controls Connect the control lines that were started in Step 7 of Stage 2 to the rudder and elevator by running them first through the eyelets on Frame 6 FC6 in the order Cable from left rudder pedal through left eyelet to left rudder control horn TP11 One Cable each from top and bottom of control stick through...

Страница 31: ...of the fuselage as shown on Sheet A It sticks straight down just behind Frame FC5 Install the two Lift Handles FC16 that straddle Frame FC8 and stick out at 45deg as shown on Sheet A and in Figure 3 5 Stage 4 Building the Landing Gear Part Number Name Count Material LC1 Wheel disk outer 2 Cast Britannia LC2 Wheel disk inner 2 Cast Britannia WPA013 LO1 Tire 2 Cast Rubber O ring LC3 Nut 2 Cast Brita...

Страница 32: ...g gear is shown in Figure 4 1 Figure 4 1 Landing Gear Cut the stock material LM1 6 to the lengths in the parts list Paint the struts LC4 LC5 the wheels LC1 LC2 and the nuts LC3 red Either leave the Landing Gear Spar LM 3 brass or paint it silver to better match the front and rear spars LM5 If you do paint it mask off the ends where the struts will be glued Glue the four Center Ribs LW1 to the Land...

Страница 33: ...Le Rhőne which was manufactured by Oberursel and called the UR II the engine modeled in this kit Part Name Count Material EC1 Crankcase front 1 Cast Britannia EC2 Crankcase 1 Cast Britannia EC3 Cylinders with spark plug 9 Cast Britannia EC4 Intake manifold 9 Cast Britannia EC5 Crankcase rear 1 Cast Britannia EC9 Carburetor 1 Cast Britannia EC10 Front mount accessories 1 Cast Britannia EC11 Rear mo...

Страница 34: ...the cowl and everything aft Pilots wore face scarves to keep from swallowing the castor oil as it is a purgative Since the oil is not re circulated the left half of the fuel tank is actually and oil tank Fuel is gravity fed to the carburetor which really was very crude only controlling the amount of air the engine received The ignition is through a magneto which is part of the front mount EC10 Thi...

Страница 35: ...ngine Details Paint the intake manifold portion of EC4 bright copper and the valve train portion black Glue in place on each cylinder Make the push rods EM4 from 1 16 1 6mm brass rod and glue in place They are about 75 19mm long but need to be cut to length And add the spark plug wires EM5 016 4mm wire Both of these parts are shown in detail drawings on Sheet E The front and rear mounts EC10 and 1...

Страница 36: ...on the propeller at this time Later the propeller may be glued to the engine or if you want to get cowl off to show the engine detail just mount it on the shaft with a snug fit Figure 5 3 Propeller Stage 6 Building the Cockpit and Connecting the Controls to the Engine Part Name Count Material EC10 Front mount accessories 1 Cast Britannia EC11 Rear mount 1 Cast Britannia FP1 Firewall 1 010 photo et...

Страница 37: ... 6 1 Two wires one thick and one thin connect to the synchronizer the two center posts on EC10 The thick one supplies a signal from the engine to only fire the machine gun when the propeller is not in the way The thin wire goes to the stick yoke where thumb switches control when the pilot wants to fire the guns These are both part of the interrupter system devised by Fokker so that the guns can fi...

Страница 38: ...aft slightly to make sure of this fit See section view on Sheet A for placement Run the four machine gun wires the blip switch wire the tachometer and magneto wires under the spent ammo can to the cockpit area You can bundle the wires going to the control yoke together as shown in Figure 6 2 Note that the Ammo Can will sit just aft of Frame 3a but don t install it yet C Control yoke Part Name Coun...

Страница 39: ...n or gray Paint the Tachometer FC22 black taking care not to paint the face Cut out the Tachometer dial from the sheet supplied Holding the Tachometer body face up put the dial FO4 in the recess and add a couple of drops of Cyanoacrylate When hard it will make a clear lens Mount the tachometer to the bottom of the ammo can assembly 12 6mm from the left side of the can exact placement is not critic...

Страница 40: ...ve on the left side This is the fuel outlet and the value is the fuel shut off The other post on FC11d without the valve is the oil outlet Form tank skins FP8 and FP9 to fit tank rim FC11a by bending them around a 3 32 dia rod 2 5mm Make sure that cutouts for the filler pipes and gage on top and outlet on bottom align The skins FP8 and 9 will need additional cuts to clear the outlet pipes and may ...

Страница 41: ...belt H Final Cockpit Details Part Name Count Material FC 21 Compass 1 Cast Britannia FC4a Fuselage frame 1 Cast Britannia FO6 Compass dial 1 Paper card Paint the body of the compass FC21 copper or brass Do not paint the face Add compass dial FO6 and add cyanoacrylate lens Epoxy compass to the floor board as shown in the layout on Sheet A Add Frame FC4a now that the cockpit details are complete Now...

Страница 42: ... ammo can under the machine guns and glue to the ammo can as it is nearly impossible to glue them to the bottom of the guns and this joint cannot be seen B Installing the lower and middle wings With the lower wing in the assembly jig glue the spar to the fuselage frame The wing spar should fit nicely in the notches in the fuselage sides FC1 The middle wing should sit on the top of the fuselage sid...

Страница 43: ... Right 1 010 Photo etched aluminum FP26 Fuel gage windscreen 1 Paper stock WPC064 Coaming stock Rubber tubing WP3625 Machine gun padding stock 3 32 square bass wood 2 4 mm FW2 Cheeks 2 1 64 laser cut plywood 1 Turtle deck The turtle deck FW3 can now be added as shown on Sheet A Soak it in water and form it over a bottle to get the round shape Trim it to fit the cockpit opening and fuselage and glu...

Страница 44: ...ke some trimming and bending 3 Coaming and padding The cockpit edge is now fully defined by the turtle deck and sheet metal so the coaming can be added It is made from rubber tubing slit to fit over the turtle deck and sheet metal Figure 6 4 Padding on the back of the machine guns is made of three pieces of 3 32 square basswood 2 4mm glued together to make an U shape see detail on Sheet D and the ...

Страница 45: ...he top wing Add the outer struts aligned with those between the middle and bottom wings Add bracing with turnbuckles between the front struts as shown in Figure 7 3 If all is well the machine guns should be aimed to fire under the bracing wires G Stringing the Aileron Cables The aileron cables can now be run from the bellcrank between the ammo can and Frame 3a and up through the pulleys as shown i...

Страница 46: ...phy of each of the crew members short though they may have been Also noted is the type of aircraft flown by both Richthofen and his advisories and any discrepancies between the Baron s reports and those by the Allies and other witnesses Windsock Datafile Special No Fokker Dr I Jagdstaffeln Greg Van Wyngarden Albatros Productions Limited 2007 Excellent set of drawings of the Dr1 Sopwith Camel VS Fo...

Страница 47: ...47 ...

Страница 48: ...s Sopwith Camel MA1030 Albatros MA1001 Nieuport 28 MA1002 Curtiss Jenny MA1010 Wright Flyer MA1020 Manufactured by Model Shipways Inc dba Model Expo Hollywood Florida Sold by Model Expo a division of Model Shipways Inc http www modelexpo online com ...

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