New Images!-AIR ZOO's 1943 Fairchild PT-23-In Flight & Interior Vie
Posted: Sat Jul 03, 2004 2:33 pm
'Please click on the "PHOTOS" link located in the left margin
of the
Fairchild Club Home Page to see the newly added "AIR ZOO"
Folder.
Inside, I uploaded several fresh images of the Kalamazoo AIR
Zoo's
1943 vintage Fairchild PT-23HO. Some pictures were photographed
"in-
flight" from the Air Zoo's 1929 vintage Ford 5AT Tri-Motor,
while
others include several nice cockpit-interior details. If you
interested in "close-up" views, just click on the "view
full-size"
link above each image to zoom in even more.
My name is Greg Ward. I am the Curator of Restoration for the
Kalamazoo Air Zoo. I have worked for the K.A.H.M. for 17 years to
date.
My very first "complete" restoration project was this particular
Fairchild PT-23, originally built by Howard. (H0291) Registration
Number N52020.
Tom Austin, of Greenville Tennessee, donated this machine to the Air
zoo in 1988.
Tom's Father used to own a PT-23 after the war, so that was one
reason why Tom purchased this particular brand of airplane. He had
every good intention of restoring it, and later spending quality
time flying it with his Dad. Unfortunately, once Tom found himself
deeply overwhelmed by the woodworking portions of the project, he
made the difficult decision to bail out and cut his losses. The good
news, for us, was that he decided to gift it to the Air Zoo.
(Tom was a regular Air Zoo pilot at the time, flying our F6F
Hellcat, T-28 Trojan, and T-6 Texan.
Either way, he was hoping that the PT-23 would eventually be
restored to airworthy status, and that perhaps he and his Dad would
get the chance to enjoy that long overdue flight-time together.
Air Zoo mechanics then evaluated the project. They all promptly
decided that it was too intense "woodworking-wise." They
mentioned
that sheet metal was their true specialty. I graduated from
Pittsburgh Institute of Aeronautics about one month after the
airplane arrived in Kalamazoo. Luckily, the Air Zoo hired me in as a
full-time A&P Mechanic. My life was about to change forever.
I studied the museum's PT-23 project in detail, reading about it
in
books, and spent countless hours on the telephone with Mike Kelly,
John Berendt, and many other knowledgeable Fairchild Club members.
Since my background was primarily wooden-boat building, as well as
iceboat design and construction, I was beginning to feel qualified
enough to proceed. After discussing the facts with even further with
Mike, in person, I approached the Air Zoo's Director, Bob Ellis. Bob
granted permission to proceed with the restoration of a small part,
initially. I believe that he felt that it was important to test my
skill-level before pressing on. Not to mention the enormous cash-
outlay that was looming on the horizon! The Air Zoo always restores
their aircraft 100%. No stone is ever left unturned! That is when I
learned the difference between total restoration and a simple face-
lift. This is the primary reason why I love to work there every day.
They do everything the right way, only the best!
I began working on the vertical fin that very same evening. Our I&A,
Dick Schaus, observed, inspected and approved that part over the
course of the next few weeks until it was finished. We then moved on
to the flaps, floorboards, belly-cage, luggage compartment and
turtle-deck.
One year later, we began working on the horizontal stabilizer. The
stab was a very challenging project to say the least! Our particular
unit had "fully-tapered" dura-mold skins on both top and
bottom. In
other words, the center portions of skin contained seven
laminations, then twelve inches out on either side of the CL; the
manufacturer terminated the seventh veneer inside bringing the
number down to six layers. Twenty-four inches out from the center
the number dropped to five and so on. In a nutshell, after we
replaced the main spare with new material, we re-skinned the stab
with 3/32" 3-ply mahogany ply, initially, followed by a second
layer
of 1/16" ply in 6" wide strips. Our end-result yielded a much
stronger stabilizer that was skinned at such a thickness that it
matched up with the center 24" portions of the original. The only
difference was that our new product would sport a skin of a
consistent thickness across its entire span. The FAA was perfectly
OK with that decision. Sure, there were several more ounces of extra
weight, but then, it really didn't seem to matter when weighed.
The outer wing panels were next. We removed the bottom skins of both
wings and performed all of the necessary repairs from inside. (From
the trailing edge regions to the rear face of the main spar)
Afterward, we removed the skin from the leading edge ribs starting
at the bottom of the main spar, around the forward portions of the
leading edge, and up to the top of the main spar "only". I
built
custom full-sized bending jigs to help pre-bend the new skin. (A
left and a right) Bending the plywood was accomplished by means of
utilizing cargo ratchet-straps, to suck the moistened plywood down
tightly over the form. The entire process took over one calendar
month for each wing panel.
We saved the construction of the new center section for last.
We utilized a powerful Porter-Cable router, countless router bits,
4" electric portable power planer, razor sharp chisels, hand
tools
of all other types, and belt sanders, for what seemed like years!
Lyle Patton, one of my most qualified volunteers at the time, used
to work for Brunswick Company inside their woodworking division.
Therefore, Lyle was the man who introduced us to the many production-
line procedures, incorporating jigs and fixtures throughout this
project. I really do have Lyle to thank for most of what I know
today, and the fashion in which work on my own personal airplane or
iceboat projects.
NOTE: Currently, my Father and I are restoring a 1946 Johnson Rocket
(Serial #10) The Rocket 185 contains many of the very same
challenges as the Fairchild and more. A sheet metal front end,
wooden wings and tail surfaces, rag & tube fuselage and the like.
The Rocket also houses a retractable gear and hydraulic flaps,
adding even more to the restoration work-effort. I wouldn't feel
as
confident to handle such a project without the extensive experience
that was gained from that PT-23 project!
Eight years and over $80,000 later, we were flying the newly
restored PT-23 to Oshkosh! The result of our effort was a "Judges
Choice" plaque in the Warbird arena. To say that we were all busting
a few buttons that evening would be a gross understatement!
A strange dilemma?
During the return trip home, Tom Austin mentioned that
we were experiencing a loss of airspeed for some unknown reason? I
quickly eyeballed the airspeed indicator inside the rear cockpit and
our speed appeared to be reading normally there?
After another few minutes had elapsed, Tom mentioned over the
intercom that he finally figured it out. Our "excessive-drag"
condition was attributed to my swollen ego, and big head protruding
above the windscreen! We both laughed hysterically for quite some
time afterward! NOTE: Two pilots laughing at the same time over a
voice-activated intercom system sounds very, very strange! These
systems were not designed for such hysterics.
We love it?
The Fairchild PT-23 has to be one of the most pleasurable, stable-
flying airplanes that I have ever had the pleasure of operating. At
one point during the return trip to Kalamazoo, Tom noticed that we
appeared to be drifting off course? It was at that time that I told
him not to worry, that the deviation was due to the fact that my
arms had been crossed over my chest with both feet resting flat on
the floor for the past 25 minutes. (I set the timer on my wristwatch
to keep track) I was curious to know how far this sweet machine
could fly without help from us. That aircraft was trimmed
flawlessly! Those are the kinds of fond memories that will always
stand out in my mind every time I see a Fairchild Primary Trainer.
There is no way to fully explain the wonderful feeling to other
folks, of what it was like to hear those tires chirp safely onto the
Oshkosh asphalt, wearing an airplane that had been previously
restored using our own hands. Down both sides of the Oshkosh
taxiways, cameras were flashing and video camcorders were rolling,
all the way to our parking spot! Now I understand why Hollywood
celebrities get hooked on cameras and the spotlight! We felt like
shining stars that day with our shiny Imron painted wings gleaming
in the sunshine! The thought of winning a plaque or trophy really
meant nothing at that very moment, since we felt that we already won
through personal enrichment, job satisfaction and pride.
Today?
The Air Zoo's PT-23 is parked for now. Our Air Zoo Flight Program
is
currently "on-hold" for insurance reasons. In the meantime, the
Fairchild is proudly displayed inside the new AIR ZOO and standing
ready for close inspection.
GREAT NEWS: Our new AIR ZOO just opened May 1, 2004!
Whether you find yourself close to Kalamazoo, Michigan or not,
please, plan a day or two experiencing our new (indoor) fully
interactive aviation-based theme attraction. This huge new facility
is fully air-conditioned for comfort. "World-class"
doesn't even
begin to describe the amusement-park environment inside. This new
facility is family friendly, high-tech, and very much one-of-a-kind!
The main exhibit area alone measures out at a whopping 120,000 sq.
ft. The main floor measures in at 200' x 400'. The walls are adorned
with the world's largest hand-painted mural, towering above the
floor at over 32' in height!
Famous aviation artist Rick Herter spent over a year painting the 32'
x 900' mural around the main exhibit area's perimeter. On May
1st,
the Guinness Book of World Records attended our Grand-Opening to
award the Air Zoo with a plaque, declaring Rick's painting to be the
world's largest indoor hand-painted mural!
If you would like to see some beautiful full-color pictures of the
Air Zoo's interior, and Rick's spectacular wall mural, then
please,
feel free to join my yahoogroups site:
http://groups.yahoo.com/group/flightcenter2/
Also visit the "official" Air Zoo website to make your vacation
plans now: www.airzoo.org
"FAIRCHILDS FOREVER!"
Respectfully,
Greg'
of the
Fairchild Club Home Page to see the newly added "AIR ZOO"
Folder.
Inside, I uploaded several fresh images of the Kalamazoo AIR
Zoo's
1943 vintage Fairchild PT-23HO. Some pictures were photographed
"in-
flight" from the Air Zoo's 1929 vintage Ford 5AT Tri-Motor,
while
others include several nice cockpit-interior details. If you
interested in "close-up" views, just click on the "view
full-size"
link above each image to zoom in even more.
My name is Greg Ward. I am the Curator of Restoration for the
Kalamazoo Air Zoo. I have worked for the K.A.H.M. for 17 years to
date.
My very first "complete" restoration project was this particular
Fairchild PT-23, originally built by Howard. (H0291) Registration
Number N52020.
Tom Austin, of Greenville Tennessee, donated this machine to the Air
zoo in 1988.
Tom's Father used to own a PT-23 after the war, so that was one
reason why Tom purchased this particular brand of airplane. He had
every good intention of restoring it, and later spending quality
time flying it with his Dad. Unfortunately, once Tom found himself
deeply overwhelmed by the woodworking portions of the project, he
made the difficult decision to bail out and cut his losses. The good
news, for us, was that he decided to gift it to the Air Zoo.
(Tom was a regular Air Zoo pilot at the time, flying our F6F
Hellcat, T-28 Trojan, and T-6 Texan.
Either way, he was hoping that the PT-23 would eventually be
restored to airworthy status, and that perhaps he and his Dad would
get the chance to enjoy that long overdue flight-time together.
Air Zoo mechanics then evaluated the project. They all promptly
decided that it was too intense "woodworking-wise." They
mentioned
that sheet metal was their true specialty. I graduated from
Pittsburgh Institute of Aeronautics about one month after the
airplane arrived in Kalamazoo. Luckily, the Air Zoo hired me in as a
full-time A&P Mechanic. My life was about to change forever.
I studied the museum's PT-23 project in detail, reading about it
in
books, and spent countless hours on the telephone with Mike Kelly,
John Berendt, and many other knowledgeable Fairchild Club members.
Since my background was primarily wooden-boat building, as well as
iceboat design and construction, I was beginning to feel qualified
enough to proceed. After discussing the facts with even further with
Mike, in person, I approached the Air Zoo's Director, Bob Ellis. Bob
granted permission to proceed with the restoration of a small part,
initially. I believe that he felt that it was important to test my
skill-level before pressing on. Not to mention the enormous cash-
outlay that was looming on the horizon! The Air Zoo always restores
their aircraft 100%. No stone is ever left unturned! That is when I
learned the difference between total restoration and a simple face-
lift. This is the primary reason why I love to work there every day.
They do everything the right way, only the best!
I began working on the vertical fin that very same evening. Our I&A,
Dick Schaus, observed, inspected and approved that part over the
course of the next few weeks until it was finished. We then moved on
to the flaps, floorboards, belly-cage, luggage compartment and
turtle-deck.
One year later, we began working on the horizontal stabilizer. The
stab was a very challenging project to say the least! Our particular
unit had "fully-tapered" dura-mold skins on both top and
bottom. In
other words, the center portions of skin contained seven
laminations, then twelve inches out on either side of the CL; the
manufacturer terminated the seventh veneer inside bringing the
number down to six layers. Twenty-four inches out from the center
the number dropped to five and so on. In a nutshell, after we
replaced the main spare with new material, we re-skinned the stab
with 3/32" 3-ply mahogany ply, initially, followed by a second
layer
of 1/16" ply in 6" wide strips. Our end-result yielded a much
stronger stabilizer that was skinned at such a thickness that it
matched up with the center 24" portions of the original. The only
difference was that our new product would sport a skin of a
consistent thickness across its entire span. The FAA was perfectly
OK with that decision. Sure, there were several more ounces of extra
weight, but then, it really didn't seem to matter when weighed.
The outer wing panels were next. We removed the bottom skins of both
wings and performed all of the necessary repairs from inside. (From
the trailing edge regions to the rear face of the main spar)
Afterward, we removed the skin from the leading edge ribs starting
at the bottom of the main spar, around the forward portions of the
leading edge, and up to the top of the main spar "only". I
built
custom full-sized bending jigs to help pre-bend the new skin. (A
left and a right) Bending the plywood was accomplished by means of
utilizing cargo ratchet-straps, to suck the moistened plywood down
tightly over the form. The entire process took over one calendar
month for each wing panel.
We saved the construction of the new center section for last.
We utilized a powerful Porter-Cable router, countless router bits,
4" electric portable power planer, razor sharp chisels, hand
tools
of all other types, and belt sanders, for what seemed like years!
Lyle Patton, one of my most qualified volunteers at the time, used
to work for Brunswick Company inside their woodworking division.
Therefore, Lyle was the man who introduced us to the many production-
line procedures, incorporating jigs and fixtures throughout this
project. I really do have Lyle to thank for most of what I know
today, and the fashion in which work on my own personal airplane or
iceboat projects.
NOTE: Currently, my Father and I are restoring a 1946 Johnson Rocket
(Serial #10) The Rocket 185 contains many of the very same
challenges as the Fairchild and more. A sheet metal front end,
wooden wings and tail surfaces, rag & tube fuselage and the like.
The Rocket also houses a retractable gear and hydraulic flaps,
adding even more to the restoration work-effort. I wouldn't feel
as
confident to handle such a project without the extensive experience
that was gained from that PT-23 project!
Eight years and over $80,000 later, we were flying the newly
restored PT-23 to Oshkosh! The result of our effort was a "Judges
Choice" plaque in the Warbird arena. To say that we were all busting
a few buttons that evening would be a gross understatement!
A strange dilemma?
During the return trip home, Tom Austin mentioned that
we were experiencing a loss of airspeed for some unknown reason? I
quickly eyeballed the airspeed indicator inside the rear cockpit and
our speed appeared to be reading normally there?
After another few minutes had elapsed, Tom mentioned over the
intercom that he finally figured it out. Our "excessive-drag"
condition was attributed to my swollen ego, and big head protruding
above the windscreen! We both laughed hysterically for quite some
time afterward! NOTE: Two pilots laughing at the same time over a
voice-activated intercom system sounds very, very strange! These
systems were not designed for such hysterics.
We love it?
The Fairchild PT-23 has to be one of the most pleasurable, stable-
flying airplanes that I have ever had the pleasure of operating. At
one point during the return trip to Kalamazoo, Tom noticed that we
appeared to be drifting off course? It was at that time that I told
him not to worry, that the deviation was due to the fact that my
arms had been crossed over my chest with both feet resting flat on
the floor for the past 25 minutes. (I set the timer on my wristwatch
to keep track) I was curious to know how far this sweet machine
could fly without help from us. That aircraft was trimmed
flawlessly! Those are the kinds of fond memories that will always
stand out in my mind every time I see a Fairchild Primary Trainer.
There is no way to fully explain the wonderful feeling to other
folks, of what it was like to hear those tires chirp safely onto the
Oshkosh asphalt, wearing an airplane that had been previously
restored using our own hands. Down both sides of the Oshkosh
taxiways, cameras were flashing and video camcorders were rolling,
all the way to our parking spot! Now I understand why Hollywood
celebrities get hooked on cameras and the spotlight! We felt like
shining stars that day with our shiny Imron painted wings gleaming
in the sunshine! The thought of winning a plaque or trophy really
meant nothing at that very moment, since we felt that we already won
through personal enrichment, job satisfaction and pride.
Today?
The Air Zoo's PT-23 is parked for now. Our Air Zoo Flight Program
is
currently "on-hold" for insurance reasons. In the meantime, the
Fairchild is proudly displayed inside the new AIR ZOO and standing
ready for close inspection.
GREAT NEWS: Our new AIR ZOO just opened May 1, 2004!
Whether you find yourself close to Kalamazoo, Michigan or not,
please, plan a day or two experiencing our new (indoor) fully
interactive aviation-based theme attraction. This huge new facility
is fully air-conditioned for comfort. "World-class"
doesn't even
begin to describe the amusement-park environment inside. This new
facility is family friendly, high-tech, and very much one-of-a-kind!
The main exhibit area alone measures out at a whopping 120,000 sq.
ft. The main floor measures in at 200' x 400'. The walls are adorned
with the world's largest hand-painted mural, towering above the
floor at over 32' in height!
Famous aviation artist Rick Herter spent over a year painting the 32'
x 900' mural around the main exhibit area's perimeter. On May
1st,
the Guinness Book of World Records attended our Grand-Opening to
award the Air Zoo with a plaque, declaring Rick's painting to be the
world's largest indoor hand-painted mural!
If you would like to see some beautiful full-color pictures of the
Air Zoo's interior, and Rick's spectacular wall mural, then
please,
feel free to join my yahoogroups site:
http://groups.yahoo.com/group/flightcenter2/
Also visit the "official" Air Zoo website to make your vacation
plans now: www.airzoo.org
"FAIRCHILDS FOREVER!"
Respectfully,
Greg'