August CAF Red Tail Update | AirCorps Aviation

by Chuck Cravens

This is a front view of fuselage with lower cowl former and also note that the side cowl former has been dimpled and the Dzus springs installed.

Update

Last month’s update was produced early to have a current status report at AirVenture in Oshkosh, so this month’s update covers a slightly longer period.

We ended last month with the hope that the Merlin would arrive soon from Roush Aviation. It did come in the last week of July as you will see in the photographs.

Fuselage

Fitting of skins, windows and accessories were the main thrust of the repairs to the fuselage this month.

The left side cowl skins are clecoed on for fitting in this shot.

Right side view showing reused skin panel with Tuskegee prominently visible.

Forward air induction duct is being readied to be drilled for rivets.

Cowl

Ryan works on the lower rear cowl skin.

The metal is formed but undrilled for the lower rear cowl skin.

Ryan working on a structural rib for the cowl.

A front view with the lower forward cowl piece clecoed on.

Here is a side view showing forward lower cowl.

Curved “D” window panels await fitting.

Rear view shows the red horizontal and vertical stabilizers, the rudder will become red when the entire Mustang is repainted.

This trim tab control linkage detail shot shows how the trim tab connects to the pushrod that activates it.

Ryan is working on making the structure ready for the aluminum “smile”casting.

New radio bracket Aaron made for the ADS-B radios is in place.

“D” Windows

Aaron concentrates as he works on systems in the rear cockpit.

The left side “D” window is temporarily installed.

Brent cleans the ‘D” window after it has been seam sealed and the inside frame painted.

The “D” windows are drying after frame painting in this image.

Here is how the “D” windows look installed after the frames were painted.

The lower cowling former is being fitted in this shot.

This left side view shows the former permanently riveted in.

This is a front view of fuselage with lower cowl former and also note that the side cowl former has been dimpled and the Dzus springs installed.

Here is a similar view from a higher angle.

Ryan needs to patch a crack in the right hand side cowl by spot welding a patch. Here he is setting up the spot welder for that job.

Ryan tests the weld penetration on scrap aluminum before welding the actual part.

Ryan has the side cowl former to be patched with the spot welder.

The chin cowl is ready for fitting, notice the doublers where the air filter box covers will be.

Here’s a nice view of Ryan working on the fitting with Tuskegee Airmen in the background.

This is an original air filter box cover that is a used but serviceable part.

Ryan is carefully trimming the doubler.

This is a closer view as Ryan trims.

Chips fly as the grinder bit takes off aluminum.

Engine

As promised, the Packard Merlin arrived all repaired and ready to go from Roush Aviation. They do great work and it is always exciting when the power plant goes in. First the mounts need to be prepared.

Front view showing the engine mounts and front of the air induction that mates to the cast “smile”.

The right side forward engine mount assembly as it appears installed

The right rear engine mount has been installed.

Another view of the right side forward mount shows the bolts attaching it to the frame.

This image is a close up of the left side forward mount.

Here we have the right side forward engine mount from the front.

Here’s the Merlin from Roush in its mounts at last.

In this front view of the installed V1650, the accessories just above the casting are the black painted hydraulic prop governor and the natural metal vacuum pump.

I love when the Merlin is installed; it is the heart of the P-51 and makes her seem to come to life.

A blast tube fitting for the carburetor air induction as it is tack welded shown here.

The weld is complete.

Three fittings are done.

The right side showing the various systems in place, ignition leads, the blast tube for cooling air to magnetos, and the oil filter all show in this image.

Kris is forming tubing to make internal header tank tubes.

The exhaust stacks are ready for reinstallation.

Stainless steel exhaust shroud shown sitting on a box of exhaust stacks. It won’t be used because it is in rough shape. We have new ones to fit.

At this point the cowl pieces have been fitted and then removed for easier access to the V1650.

Scoop

Restoring a scoop, or making a new one for that matter, can seem to take forever.

Scoop progress can be slow because it is such a complicated assembly but the Red Tail’s scoop and doghouse are being joined and are close to completion and reinstallation.

Lots of compound curves are what makes forming scoop parts so difficult.

Here is a tight image of some scoop detail.

Bottom view of scoop shows clamps in place as fitting continues.

This one is a good perspective of the new radiator in place.

Completed doghouse is ready to install.

Right side “D” window is in place with a good look at the dog house.

Front angle shot of the dog house showing the oil cooler now installed.

Front of the scoop formed and welded, notice how tight the radii of the formed aluminum curves are.

The rest of the scoop assembly is ready for the last skin assembly to the front of the scoop.

Front of the scoop is clecoed and ready for more drilling.

The scoop is being fitted to the doghouse in this view.

This perspective is the scoop and doghouse from the side that attaches to the fuselage.

Side view of the assembly as it sits on the pallet.

The overhauled oil cooler exit door actuator has been installed.

This view is another angle on the oil cooler exit door actuator

Right side “D” window is in place with a good look at the dog house.

Wings

The good folks at Odegaard Wings are repairing the wings so that, together with AirCorps, we can get this iconic Mustang back in the air. She is too important to the educational program of the Commemorative Air Force and especially the Red Tail Squadron to spend any more time in restoration than it takes to do the job right. Casey Odegaard sent these photos of the progress they are making.

Left side flap is out of the jig, ready to start on the right flap.

The left side fuel tank cover (or stress door) is repaired.

Left side gear well parts are primed and ready to rivet.

Right hand inboard leading edge skin has been installed.

Landing Gear

The final area of restorative progress on “Tuskegee Airmen“ we will examine this month is the main landing gear. A great deal of work went into getting them ready so that when the time comes to put them in, there is no delay.