|Chronological selection of photos
during final assembly.
Hangar space provided by the Aviation Training Center
... located in the school hangar at Flying Cloud Airport, Minnesota.
... a division of MCTC, Minneapolis Community & Technical College
|Kit Building||For 3 years, Dale Johnson built a "kit" for the Wright Flyer. We are now in the process of assembly these parts. Some of the team members also did some work in their homes.|
|Steve Adkins wrapping
strut ends at home. Mike Hagberg also wrapped struts.
Initial assembly of landing gear and wing sparsCenter section of lower wing and landing gear
Front motor mounts on front spar
Detail of intersection of motor mount and front spar
Installation of ribs. Sewing of wing cover.Sewing diagonal panels for lower-center wing
Lower wing (center section) and muslim covering bolt
Close up of engine mounts on lower wing
Plans for same
Sewing of wing cover, adding pockets and VelcroDale Johnson sewing cover
Claire and Dale sewing cover
Installing ribs on spars ... (middle portion of lower wing)
Wing ready for cover
Covering of middle portion of lower wingOriginal and New tools used to attach covering
Lower covering installed with "rib pockets" shown
Cord used to tie cover and wire to ribs Plans
Rib pocket in lower cover Plans
Finished: cover end view of lower side Plans for tacking
cover front view of lower side
3/4 front view ... covered!
|Built upper-center wing section|
|Sewed cover for upper-center wing section
Modified wing fittings
Installed metal fittings on lower wing
|Various||Dale modified wing fittings
Complete turning cylinders
Completed upper-center wing section, ready to installCompleted sewing cover
Installing wing cover on upper wing section (Dale, Clair and Bill shown working
... Dale, Clair and Bill ... Adkins behind camera
Installed wing fittings on upper wing section
Left early due to blizzard
Installed controversial cross-bar on tension wires behind props
|Now it is a Bi-plane!
note level on upright struts
View of under side of upper wing
Installed upper-center wing section
Clair making wire collars
Soldering iron and close-up of strut, mounting bracket, wires
Bill and Dale installing upper wing and adjusting guy wires
Corner of upper wing - showing guy wires
Planned work on scaffolding over wing deferred due to wire conflicts
- (Anybody know how the engine was dropped in place?)
Dale delivered engine parts to Dick Burns for turning on lathe
|One propellor installed and both
prop support structures
- Installation process (Bill, Clair, Dale)
- Prop shaft, mounting plate and thrust bearing close-up
- close up of mounting pipe and prop ...different angle
Installed lower pulleys for wing warping
Started assembly of right-lower, outer wing panel
Initiated sewing for right-lower, outer wing panel
Installed upper tail structure ... fitting shown (close up)
Dale Johnson continues to produce additional parts at home
|Installed upper pulleys for wing warping
Nearly completed right-lower, outer wing panel
Finished tension wires for landing skid
Front Rudder (we call it Elevator)Completed rough assembly of all remaining wings
Installed elevator and front supporting structure
Installed lower-outer-right wing section (3 installed, 3 to go)
|Installed upper right wing (4 installed, 2 to go)|
Pilot aboard! Wing Warp SaddleInstalled wing warp saddle and foot rest for pilot
Pilot aboard for the first and last time
.... more brumm... brummm
.... rear view with tangle of wires
We are having a debate about boarding ....
2nd Propellor and Rear RudderInstalled 2nd propellor and rear rudders ... more distant view
.... note faint X-wire bracing wires on front (rear side hard to see ... better view)
- Installed lower rudder braces (detail)
- Rudders mounted on pivot bar
- Stretchers mounted between rudders
- Tension wires added, rigidity results like magic
... middle tension wire (note, decided not to solder wire twist)
Dale continued sewing
Clair produced more collars and soldered wire branding onto wing-tip bows
(wire banding covered with muslin)
|Finished sewing muslin wing cover including "pockets" for wing ribs
Assembled wing including sliding cover onto wing ribs using new system
- Dale and Clair tie trailing wire to rib ends with waxed cord
- Adkins soldering bands around front end of ribs
Covered and installed 5th wing section (1 to go!)
Started installing wing warping control wires (Lift wires)
- bicycle-type chain ready for installation ... Plans of pulley ... edge view
- wing warping wire (lift wire) installed with chain through pulley
- loop soldered onto warping wire for connection to saddle and tensioning wire
Fire in the hangarDale Johnson and Steve Adkins travel to site to assess damage to Wright Flyer, take photos and preliminary clean up. Wing is partially rewired to eliminate "sag" from fire.
Adkins spends afternoon updating the website to reflect damage photos.
Johnson goes home to build additional ribs.
... Looks like we are back to (3 done, 3 to go)
|at home||Dale Johnson builds front portion of rib.
Steve Adkins adds webpage to reflect fire damage for assessment by team members.
|General clean up after fire (vacuuming and sweeping) ... interesting
burn pattern in muslin.
Right wings segments are torn down to assess damage by fire.
.... Mike Hagberg works on wing clean-up
.... unburned muslin ... note how nose rib parts are saved by screwing to board
Remaining muslin is cut to size to assess quantity remaining.
... appear to be short lacking enough to cover one lower (or upper) wing segment
Ribs and spars are sanded to remove burned portions.
Right lower wing segment is rebuilt using best parts from upper and lower wing
Upper and lower elevator covered (front rudder)
|at home||Adkins, webmaster, repairs segment of rib nearly burned through and devises better connection for false rib at wing end. A second rib with minor break is repaired.|
|Broken rear rudder lower left strut is repaired
using epoxy (OK, not authentic)
Wing warping tensioning swing wire (view 2) is added including connection loop
Wing segment 6 finished ready to install
... (6 out of 6, except segments 3 and 4 require rebuild due to fire
Metal wrap is added to glued rib for extra strength.
Elevators are nearly ready to be installed
||Repaired several ribs. Small section
glued in place shown.
Sewing on wing covers to accelerate progress.
Built additional new rib ... not needed, for trophy?
|Installed the 6th wing segment (upper-right).
Lower wing is complete.
(note: only missing segment is upper-left).
Continued repairing and sanding burned ribs for upper-right wing.
Preliminary assembly of repaired sections and new ribs for upper-right wing.
Continued work on wing warping wiring. Getting tension correct will be fussy.
Glued broken lower-strut on rear rudder.
Note: discovered on new plans a similar repair on original 1903 Flyer Plans!
||Dale Johnson finished Intake and Exhaust manifold ... view 2|
|Dale and Clair finish upper
and lower front rudders with some help from Steve
After Installation, the Wright Flyer looks ready to fly ...
... where's the engine? ... note the anhedral!
Steve and Dale begin sheet metal work using school brake to start radiator
School conducts tour of building including our Wright Flyer
|at home||Dale Johnson works on chain shown installed with close-up detail.|
|Bill Igoe graces our hangar with 3 generations
and budding pilot.
Emergency phone call bring CAD-CAM team to hangar with computer generated drawings of the funnel-shaped bottom for the fuel tank.
Extensive rewiring of wing truss wires including soldering ferrules on the wire. Much adjustment of the wing warping wires.