Gear Up!


When Champaign Lady flies in a few years, she will fly in a clean configuration, landing gear in the wells, including the tail wheel.   That our tailwheel will retract is largely due to the efforts of volunteer Fred Zerkle.   He has taken the tailwheel retraction system-- returned from Alaska-- and made a functioning, factory fresh piece of it!   It is ready to install in the fuselage. 


The retraction system was recovered from 44-85505 and was one of the prime motivations for that overall recovery effort.   These systems are quite rare and fittingly this project was trusted to a man with rare talents.  Fred has worked on many different aspects of Champaign Lady and has more than 5,000 hours of time on the project.  In that time, he has worked on radios, the fuselage, door systems, bombsight and bombardier controls, and the throttle quadrant.  His work is throughout the airplane;  the results and his dedication speak for themselves.


This restoration was a family effort.  Fred had more than able assistance from his grandsons, brothers  Chase and Liam Abbey.  Chase has been involved in the project for years and Liam is only now starting on the restoration path.   The team began work just before Christmas and Fred says the work required a little more than two weeks to complete. 

After an initial clean up and inspection, Fred wanted to see if the motor worked.   Connected to the battery system on our B-25, Fred found the system operated normally-a good omen for the restoration of this piece.

  
When facing a new challenge, Fred says the critical issue is to obtain the blueprint and conduct a thorough review.   Then compare that to the piece at hand.   There were several differences between the blue print and the piece, a common experience in this project.  For example, there were more bolts in the drive system than the print called for and the position of the electrical relays had to be reconciled.   But for Fred it was all in a day’s work.

Fred then disassembled the drive’s 24 volt motor and gear reduction; a 90 degree gear box; and a gear set and jackscrew.  He then had to build 90% of the aluminum frame that the drive system is mounted on.  The pictures shows the quality of the job.  The retraction strut itself still needs to be rebuilt and rechromed.  As for the frame of the tailwheel and the tailwheel itself, that was taken from the wreck site sometime in the past and, although it is thought to be east of the wreck site, it has not been located.  Detective work in that case continues.

Fred cleaned up the drive motor, inspected and rebuilt the 90 degree gearbox.  When he took the gear set and jackscrew apart, he found the grease to be in good condition, despite being in cold storage for 60 years!  He completely cleaned, repacked, and rebuilt the gear set system and then used a paperclip to clean the grease and dirt out of the u-joints on the emergency extension handle.  The electrical relays and the uplock and downlock switches are installed and functioning.


The system is ready to go.   So when you visit our museum or in years ahead see Champaign Lady flying with all three gear up and locked, we know the team who played a big part in that effort.

 

Written by: Robert Buchwalter

February 5, 2012

 

 


 




 
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 Beverly.jpg

Hidden treasure…no, seriously, I mean it.  Hidden treasure!

Working on this project, you learn that whatever is needed, the team can build it.  This has been demonstrated time and again!  Yet there have been occurrences that would give the equally strong impression that there are unseen souls watching over the project.   There are times when the people and parts come in the front door and seem to have been guided to us by…well, by someone.

The team has made tremendous progress on the radio room.  Approximately 120 degrees of skin on each side of the room is riveted (viewed from the rear, this would approximately be from one to five o’clock and from seven to eleven o’clock position).  The floor stiffeners are in place.  Judging from the radio room and other areas, it was time to get serious about some other major pieces in this area and chief among them was the top turret dome.

As with most other surviving Fortresses, we will not have the complete turret assembly in the airplane.  This is a large, complicated mechanism that mounts to the floor, adds considerable weight, and consumes a lot of room aft of the pilots’ seats.  We will have only the dome and the guns installed in it.

The dome itself is a steel, aluminum, plexiglass, and glass assembly.  It mounts two fifty caliber machine guns.  Plans were made to build or buy one, if possible.  On Thursday, September 16, Roger Deere dropped off a parts manual for the top turret, adding impetus to the search.  Now, we could obtain some part numbers and get serious about this acquisition.

Barely thirty minutes later, a phone call came in.   We now have a top turret dome.

Well, wasn’t that lucky?  Lucky...or something else? 

Let’s go back a few decades to the war years.  Steel Products Company of Springfield, OH, has a contract to build 350 turret domes.  Somehow, one of these domes comes into the possession of an employee of the company who decides to put it under his porch.   Whether it was a prototype, end of production piece, an article deemed scrap, we do not know.  In any case, the dome sat there, snug as a bug in a rug (or snug as a dome in the dirt) through decades of rain, freeze, thaw cycles, and subsequent owners of the house.  There it sat, undiscovered, undisturbed, unwanted, for more than 65 years. 

It is now September. 2010.  Early that month, the current owner of the house is doing some renovation and she wants to clean out the area under the porch.  Removing some lattice, she looks in and sees what she thinks is a very old television.   A friend who was helping with the clean up looks under the porch and realizes her “TV” is in fact the top turret dome for a B-17. He is familiar with the turret domes, since he was an inspector for Speco, which was formerly named Steel Products Company.  He carefully extricates the dome and brings it out into the light of day.  So now, not only does he have his hands on a very unusual piece of history, he knows the crew who might be able to use it is just a few miles away in Urbana!

He called the hangar and spoke with Randy Kemp…

On Friday September 17, Randy told the crew he had to make a run to Springfield, for reasons kept to himself.  He returns to the museum hangar with the dome and placed it on a workbench to the astounded looks of the crew!   It was slightly corroded around the base but it is a complete dome with all the plexiglass panels, bullet proof forward glass, and even some minor hardware (pulleys and springs) inside.  Since this piece was never shipped, it has no serial numbers, making it an even rarer piece, if that were possible. 

The restoration began immediately, and the turret has now been disassembled, cleaned, and stabilized.   The plexiglass panels have been soaked, cleaned, and buffed to a factory shine.  When complete, it will look brand new.  The extension cap has been reformed and at this point, work on the turret is nearly complete.  .  But our head scratching over how it came to us continues unabated.

Coincidence?  Definitely.  Lucky? Absolutely.  Explainable?  Uh, no, not exactly, unless you believe that B-17 top turret domes are often hidden under porches and discovered decades later just when a nearby Flying Fortress construction crew requires it.  This is a long shot way beyond long shots! 

The dome, once fully assembled, will be stored for a couple months before it is time to install it.   But every time we take a look at this serendipitous gift, we shake our heads.  This dome has a lot of interesting verbs attached to it: acquired, hidden, survived, discovered, given, restored, and (soon) installed!  

We cannot explain the factors that brought the dome to us.   We can only shake our heads, look skyward, and offer a smile of thanks.  So, next time you are in our hangar, take a few pictures of the dome.   It has quite a history already.  And, one day,  this piece of hidden treasure will continue its journey from under a porch in Springfield, OH,  to the sky.

 

 



 
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Our Fortress Moves to a New Castle!

We read last month of the closure of Boeing’s Plant II, where thousands of B-17s, B-29s and many other significant, historic airplanes were built and were rolled out.   It is to be razed for new construction.   All of us who appreciate the role these airplanes, their air and ground crews, and the factory workers, played in guarding our freedoms paused for a moment to note the passing of this piece of American history.  Yet, as one chapter in the history of the B-17 ends, another begins!  On Tuesday, 5 October 2010, Champaign Lady, the last “production” B-17G, was rolled out of its old hangar and toward a new home.  For the first time in 65 years, sunlight fell on a new B-17!

On that sunny day, members of the construction crew, moved 44-85813 out of our southern construction hangar and took her north to the Champaign Aviation Museum hangar, where construction will continue.   Randy Kemp, Jack Bailey, Dave Cook, Paul Good, and a host of other volunteers kept a close eye on the airplane as it was tugged north.  The forward fuselage of the airplane was supported by an ingenious steel frame that attached at the wing trunions.   In the past week, Randy Kemp attached and welded casters to the frame for the move. 

The airplane began its journey to its new home about 0930 and was in the new hangar less than an hour later.  Appropriately, Art Kemp and George Snook, two WWII air combat veterans, were on hand to escort the lady on her brief sojourn.  There are still a lot of parts and tooling to move but it is planned that by the end of October, we will be completely out of the construction hangar and all our operations will be consolidated at the Champaign Aviation Museum.

As with any move, there are many benefits to being in a new and bigger home.  But in addition to the aluminum, we will carry with us a lot of memories.  While we look forward to the new hangar, we recall the laughs and frowns, concerns and discoveries, the setbacks and accomplishments that were experienced in the south hangar.   It is funny to think that the hangar where we built so much of this airplane and shared so much of our lives is passing into that realm where we will one day refer to it as “the old place”.   And it is with sincere fondness, we remember other members of our family, those dedicated souls who are now looking down and helping us from above.      

A lot of volunteers, directed by Jack Bailey, have worked hard to prepare the hangar for this new tenant.   Our B-17 is now nestled in her new home, settled in with our B-25, A-26, C-47; and a Pitcairn Gyrocopter, Stearman, and a Wright Brothers Model B.    

It will take us a few days to sort things out but very soon, the rivet guns will bang, aluminum will be bent, the air compressor will begin to whir, and Champaign Lady will begin anew her journey to the sky.  

Written by: Robert Buchwalter
October 5, 2010

 
 

Article on Champaign Lady,

Giving a Lady New Wings

click on link below and go to page 38

 

http://digital.spiweb.com/emags/orec/2011/JAN/pageflip.html

 



 
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