Topic: Balsa USA 1/3 pup Rebuild

Thought I would get the thread going again on rebuilding my pup after its accident.

I did not build this model originally but bought it as a dream come true really.



I was in need of some help and a set of plans to rebuild this model.
It was going to be difficult as I am no great builder of models.
The Dawn Patrol lads came to the rescue with a full set of Balsa USA plans in the post. As it turned out they have been so helpful I cannot thank them enough. I will try to repay the debt at Cosford in the beer tent and any help I can give.

I salvaged one upper wing , one lower wing both needing a fair bit of repair , the centre wing section which was broken off at the fuselage . The fuselage needed the tail surfaces repairing and it had a lot of broken joints in the main structure.
Also the reduction drive to the engine was damaged along with a broken 32x18 prop.





The Fuselage looks good on first impressions but it turns out a lot of work is ahead.



Simon

Good luck with the rebuild AB  I'm sure it'll turn out fantastic 

Mud

I cleaned out the broken struts from the centre section



I had to cut away some of the top of the formers and insert new blocks to take the struts.



My workshop was not set up to take a model of this size so while I was working on that I used the second builing room, not sure the wife saw it like that.
It took me a while to get the centre section set up properly ready for gluing.
I was also trying not to disturb anything else to much at this stage. One step at a time I thought.

To make the new wings I made these templates for cutting the ribs.



After building the new wings Chris made some new clevises for his from 6mm bar stock , so i decided to copy him and make some
of my own

Making 24 gets a bit boring. I made them in a split collet in the lathe drilled out to take the square section




 I made the wires from Cycle gear cables silver soldered onto 3mm Allen bolts.



I made ply plates in the lower wings so that the wires can attach to the brackets tig  welded on to the undercarage. Before the brackets were just screwed to the fuselage.



It took a bit of setting up to get the incidences and dihedral set but its coming on nicely.
I had also altered my workshop and got rid of the bench in the middle replacing it with a couple of fold up work trestles.

The Fuselage has been repaired by removing the covering underneath. This meant that I did not need to recover the rest of it. The model before the accident had no detail bits added to it.So I thought I would have a go at adding some. All new stuff to me this.

Leather stitched around the cockpit.



I also added the stitched inspection flaps . These were made from strips of solartex with eylets set into them and then ironed onto the model.



They were then stitched up ready for paint.




The tail surfaces were striped of there covering and repaired. when I recovered them I added the imitation stitching to the surfaces made from string glued to solartex .
I painted the model using  Warbird colours from Phil at Fighteraces.



The stitching came out well.



And the stitching on the tail.




Simon

Looking good Simon, I'm glad you managed to get it back together again.

Sym.

Simon you are slacking, I was watching the rebuild posts every day now they have stoped .hope its not another dose of man flu

Alan

I'm glad you restarted your rebuild thread, I have been lurking in the back here watching it with much interest 

Simon you are slacking, I was watching the rebuild posts every day now they have stoped .hope its not another dose of man flu

Alan

Sorry , Not much happening.
Will post some pictures tonight.
Simon

Simon,
        You are doing a remarkable job of the rebuild mate The thought of rebuilding a model from what was left in your opening picture can seem so daunting, but the rewards speak for them self's, and It's giving you the chance to incorporate all those little scale changes you wanted to do when you first bought it. I actually got what was left of a model back out of the wheelie bin once just before the bin men turned up, because some one challenged me to rebuild it. The only reusable section was the left wing panel & the centre section But I'm so glad I done it now looking at the prestine model again
Top job mate

Simon,
        You are doing a remarkable job of the rebuild mate The thought of rebuilding a model from what was left in your opening picture can seem so daunting, but the rewards speak for them self's, and It's giving you the chance to incorporate all those little scale changes you wanted to do when you first bought it. I actually got what was left of a model back out of the wheelie bin once just before the bin men turned up, because some one challenged me to rebuild it. The only reusable section was the left wing panel & the centre section But I'm so glad I done it now looking at the prestine model again
Top job mate

Really glad I have done it, looking back it was a lot of work and I am no builder of scale models but I am enjoying it and it has made me think of building something from scratch and putting some of the things I have learnt into a model. It was lucky that when it crashed I walked away from it for an hour or so. If I had not done that I think it would have all been in a bin bag, but because I waited I took great care in picking up the bits and that saved the fuselage even though internally there was a lot of damage. Its not going to be a proper scale model as I have done many things wrong but for sure its going to put the biggest smile on my face seeing it flying buy on a nice low pass , which is all that matters really.

Simon

This is my attempt at the writing . I drew it out freehand trying to copy the picture of the real one best I could.
I then traced it onto the model using carbon paper. It was then a case of filling it in with paint . I decided I am rubbish at this bit.



I then drew the roundels on with a compass and filled them in by hand, at the same time painting the rudder.



I used the same carbon paper method to produce the number 4



I have just started making some more stitching for the centre section. Its unbelievable how much cord you use on this.
I used Solartex with thin cord glued onto it and cut into strips made on this little jig. My cord is a little to thick but you live and learn. Thats the next job to get the centre section finished and painted.



Its taken me well over a week to get this far doing a couple of hours after work.

Simon

Simon, nice job, is that WBC used for the roundels, and did you use it straight or thinned?

Steve

If your Pup is the one flown by Capt A S G Lee numbered B1777 it had the text "BRITISH GUIANA No2" above the CHIN CHOW if that's of any help.  I got this info from "Sopwith pup Aces of WW1" book.

Simon, nice job, is that WBC used for the roundels, and did you use it straight or thinned?

Steve

Yes it is all WBC . I painted it on using about 5% water. Found this helped it flow better.

If your Pup is the one flown by Capt A S G Lee numbered B1777 it had the text "BRITISH GUIANA No2" above the CHIN CHOW if that's of any help.  I got this info from "Sopwith pup Aces of WW1" book.

Yes it is B1777.
I still have to do that but at the moment I am not sure how to go about it. Its small writing and I had enough trouble with the big stuff.  Also I need to do the white on the outside of the roundels but that dose not seam easy as well. I am not good at using a paint brush.
If I did it again I would spray everything and get low tack maskes cut for it all. I could handle that ok I think.

Simon

for the white ring use a ink pen compass



you can just the nib to suit you paint.  using one of these you can do the inside and outside of your roundels and just fill in with a brush, it gives you a nice edge to work to.

for the white ring use a ink pen compass

Or for the big ones butcher the ink pen compass and knock up some trammels



Oh, and don't forget to tack a bit of 1/32 or 1/16 ply to the centre to support the point

Alan

Ink Pen bit on order. Thanks chaps.

Been working on it tonight.

Centre section is covered and being painted. added the stitching and edging tapes as well.



I have found these foam brushes perfect for applying the colour. Gives very light brush marks and great coverage. Called Jenny Brushes.



Also painted the control horns and cables black . I think they look much better.



I also have started putting the support wires on the tail. I am using these small turnbuckles and shackles rather than quick links , I think they will look so much better than quick links. Once lock wired up they will be great .



Simon

I have found these foam brushes perfect for applying the colour. Gives very light brush marks and great coverage. Called Jenny Brushes.

Now you tell me After I struggled with, well, ........... a brush :sm99: 

Never mind, next time

Alan

Hi AB..

Rebuild is superb - I had to do a similar one last year after stuffing my 1/3 pup in at Wings and Wheels..

re the turnbuckles on the tailplane..Are they 2mm or 3mm? I ask as the tail plane does move a bit on these  - especially as it is only a flat section as opposed to a stiffer aerofoil section.

The brass is actually less than 2mm and is very very soft  - they quickly break especially as there seems a lot of the threaded part showing on yours.

I have a smaller 30% Bristol M1  - I have had to replace all the turnbuckles on that for the same reason.

Jez

Thanks Jez.
They are only 2mm ones.
Perhaps I will change them on the tail then for something else. Shame as they look good.

Simon

Now this is just the sort of thing we have been going on about. Good stuff. Can you let us all know where you obtained the shackles from? Ken  ;copper;

Now this is just the sort of thing we have been going on about. Good stuff. Can you let us all know where you obtained the shackles from? Ken  ;copper;

Hi Ken.
I got them from this guy. Very good service. He always has them in stock along with the turn-buckles.

Regards Simon

http://cgi.ebay.co.uk/Model-boat-fitting-Four-Brass-Shackles-7mm-long_W0QQitemZ370148242532QQcmdZViewItemQQptZUK_ToysGames_ModelKits_ModelKits_JN?hash=item370148242532&_trksid=p4634.c0.m14

Got some work done on the engine.
the drive shaft was bent so a new one was ordered from Phil at Fighteraces. I also ordered a new pair of drive belts and exhaust gasket for the 38.

The old set up was a bit of a mess so a revamp was in order. There was more exhaust gas coming out of the leaks than the outlet pipe I think.



I made a new expansion chamber come silencer from stainless steel tube Tig welded together. The old 38 exhaust needed a lot of silver soldering up to seal the leaks. This was then silver soldered onto the new stainless section.



I fitted the new belts and drive shaft .



I had refinished the bulkhead and fitted formers to hold the new servos. The old ones were fitted under the pilot and it was all a bit of a lash up.



I also fitted a replacement carb with a built in choke and inlet trumpet. I bought this second hand from this site. It was fitted to a Z62 but I am sure its fine on the 38.



With the new servos fitted and new linkages made its ready for a run.

Don't quote me but I believe the bore on the g62 will be a lot larger than the 38 one and is not suitable

Bl@@dy nice exhaust, nice job

differant jetting on the 38/62 too.

  thought i would re post some photo,s from mine while im here.

  first one, new engine fitted to new firewall on iso mount.

next one cowl trial fitted

underside holes in cowl cut

under fus air exit


  chris

Don't quote me but I believe the bore on the g62 will be a lot larger than the 38 one and is not suitable

I have High hopes for it. I have done a similar thing before and it was fine with a twiddle of the mixture screws.  
Should get it run up in the week so I will know then. . Just a couple more painting jobs to do and it can come out of the workshop and into the hanger where it belongs. Then onto finishing the wings off.The end is in site. ::cc

more !!

   new wing tip one of three damaged in crash.

   new fus side all new from firewall back to md cockpit

  rebuilt re attached centre section

   chris

bored yet  

   the new clevses determined these wont break, trying to get these made in numbers by a local company if i can get enough interest.

  joystick assy

   joystick and rudder bar, i have a few of these rudderbars made also in 1/4 scale and just for the hell of it 1 at 1/2 scale.

 ps

 in the proccess of putting a complete cockpit set together, i made lots of bits, ie rudder bar, joystick footboard assy with mounting beams and a seat,  do you think it would sell ??

  chris

  

I am sure there would be a big interest in the clevises Chris. You just cannot find 3mm ones like that. I had to do what you did and make my own. 2mm ones slightly smaller for other rigging would be good as well. The shape just looks so much better than a normal clevis.
Not to sure about the cockpit kits. Part of the fun is making it,especially when you get to these size models.

Simon

Not to sure about the cockpit kits. Part of the fun is making it,especially when you get to these size models.

Simon

Depends on whether you have access to lathes etc..

I would defo have one off you for a N28c.

jez

What sort of RPM should I be getting on the geared 38 . Should get it run up this week. If I remember is it 600 rpm at tick over.
Have no Idea what full throttle is though.

Simon

I would imagine somewhere around 2700 about right at full throt. I'd say it is more important though to have a good, reliable tickover and throttling since full power is very rarely used. Wheres the pics of it all assembled Simon? Come on man, we want to see the ressurection

Very nicely rebuilt, your model looks much the better for its incident with terra firma

Ian.

speaking as another person rebuilding a pup, i cannot recomend the terror firmer method of modification 

  chris

I would imagine somewhere around 2700 about right at full throt. I'd say it is more important though to have a good, reliable tickover and throttling since full power is very rarely used. Wheres the pics of it all assembled Simon? Come on man, we want to see the ressurection

Very nicely rebuilt, your model looks much the better for its incident with terra firma

Ian.

getting there Ian

Fuselage is totally finished, just engine set up to do. No tell a lie no pilot in it yet.
3 wing panels to cover / detail and paint.
Agree with Chris ,can't recommend the terror firmer method of modification.

Simon

bored yet  

   the new clevses determined these wont break, trying to get these made in numbers by a local company if i can get enough interest.

  joystick assy

   joystick and rudder bar, i have a few of these rudderbars made also in 1/4 scale and just for the hell of it 1 at 1/2 scale.

 ps

 in the proccess of putting a complete cockpit set together, i made lots of bits, ie rudder bar, joystick footboard assy with mounting beams and a seat,  do you think it would sell ??

  chris

  

mr passion   

  chris

  all panels now recovered this weeks fun is   da dadada   da DAAAAAAAAAAAAAAAAAAAAA!!!   painting ::cc ::cc

bored yet  

   the new clevses determined these wont break, trying to get these made in numbers by a local company if i can get enough interest.

  joystick assy

   joystick and rudder bar, i have a few of these rudderbars made also in 1/4 scale and just for the hell of it 1 at 1/2 scale.

 ps


 in the proccess of putting a complete cockpit set together, i made lots of bits, ie rudder bar, joystick footboard assy with mounting beams and a seat,  do you think it would sell ??

  chris

  

Now let me think,,,,, does the Pope wear a funny hat ?? Don't think of just DP as your target market, build em and sell em this could be the start of a new  product,, afterall we make bugger all else these days
PS still havent recieved my order form