Wanted - DH Hornet Parts

[dcollins103]

Wanted - DH Hornet Parts - list updated 4th June 2013

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I have put together an updated "wants list" for the Hornet cockpit.

If anyone can help with any of the following, I would most appreciate it. (I already know of parts in Canada, Iceland, and Salisbury Hall. The collection in Scotland is now part of mine, and there is nothing left in Malta or Malaya, as far as anyone knows.) I'm looking for any unidentified parts in store rooms, museum displays, or personal collections, that the owners wouldn't mind lending or passing onto the project for either reference or measurement.

Stores tags are marked marked with 26EW for Hornet/Sea Hornet.
Also, Hornet type specific DH part numbers use the following format: The prefix is a "3" standing for DH type 103, followed by letters identifying the usage, and finally the actual part number. So a typical part number would be 3CF 1234, ie. (type 103)+(Controls, Flying )+(1234).

Letters used that I have references for are:

F = fuselage
CF = controls, flying
CE = controls, engine
T = tail
W = wing
U = undercarriage
UT = tail wheel
A = aileron

I have tried in some cases to put a photo of each.

Windscreen glazing - 3 panels
Original control grip
Nose cone (F.1-F.20 type)
Cannon blast tube fairing
Fuel c0ck lever assembly (photo 1)
Rudder pedal mounting brackets
Twin Oxygen bottle cradle
Mk.4B Gyro Gun Sight (photo 5)
Hydraulic reservoir
Two ammunition boxes
Canopy jettison mechanism (photo 2)
Canopy chain cover (photo 3)
Glycol tank (photo 4)
RH nose armour plate
LH nose armour plate

Any other Hornet parts, original manuals, photos or drawings would be most welcome too.

[Cees Broere]

Hi David,

Any updates on the project?

Just curious.

Cheers

Cees

[Peter]

David, I wish I had the parts to help but unfortunately I don't. I will keep my eyes and ears open for anything on this side of the pond for you!

[dcollins103]

Hi Cees, Peter

Good to hear from you both.

The winter months are usually my "fallow" period on the project, where construction is limited, but more drawings are made. However this last few months have seen progress on the windscreen frame. I'll post some more images soon, but ones I have to hand show the top reinforcement strips. There are a further 5 pieces of steel in this A-frame alone. The rest of the assembly is made up from 4 castings and 2 steel tie rods.

The tie rods are done, and the A- frame is now mostly cut out. It just needs drilling/folding and welding together.

It has been a big boost to get two complete canopies over the last few months also, as this confirms all of the sizes of the mating frame dimensions without doubt.

I'll be sending out more regular updates over the coming months now.

Thanks for your interest.

[Peter]

Hopefully an original windshield turns up!

[ozplane]

Have you tried de Havilland Support at Duxford?. While they probably don't have the parts themselves they may know "a man who does". They also seem to enjoy a challenge if they're not too busy.

[Cees Broere]

David,

Any progress, however small, is indeed progress.

Great work as always.

Cheers

Cees

[Whitley_Project]

Thanks for the heads up David.

[Cees Broere]

David,

What will you be doing about the canopy perspex, polish it or will it have to be remoulded.

Cheers

Cees

[dcollins103]

Hi Cees

As far as the canopy perspex goes, I'll give it a good polish for starters and see how it comes up?

The attached photo was taken when it was collected and it was covered in years of muck. It isn't perfect by any means, but at nearly 6feet long and unbroken, I'm just glad to have it.

It's a single skin type fortunately, but even so, the mould needed to recreate it would be quite big.

[Cees Broere]

David,

I saw that the B25-Mitchell tailcone that was recentely recovered from a lake had been polished to crystal clear condition, all it took was a lot of elbow-grease.

Cheers

Cees

[12jaguar]

having seen said canopy in the flesh, it is in remarkably good condition considering it had been used as a cloche for umpteen years. There doesn't appear to be any UV damage and with only minor scuff marks IMHO will polish up a treat

[dcollins103]

Here's a photo showing the two top steel components pilot hole drilled and aligned prior to folding the lower flange.

The two large diameter holes locate the pegs in the forward edge of the canopy. The remaining holes will all be drilled to size and then counter sunk to accept the bolts that secure this piece to the aluminium casting behind.

This assembly is spot welded together and then welded around its edges. It seems like belt and braces engineering to me, but that's what the drawing says!

Next to assemble are the side C-Section side channels.

[dcollins103]

Assembly now folded and welded.

[Cees Broere]

Nice job David, another step forward towards a windscreen.

Cheers

Cees

[dcollins103]

Here are a couple of photo's showing the welded assembly of the steel windscreen frame. Next in line are the 4 castings.

[dcollins103]

Can anyone recommend a good method of molding rubber sealing strip?

The section I am looking to make is three sided with a hole down the middle.

Are there any home-build, or low cost tooling methods available?

Thanks,

[Bruce]

Try COH Baines - they have a lot of sections available off the shelf - might just be something similar.


Bruce

[Tangmere1940]

Not an offer of parts but just came across this image in my archives. Thought it may be of interest to you, David.

[TwinOtter23]

Another one you could try is Tennant Rubber in Nottingham; if they cannot match the profile they can often direct you in the right direction http://www.tennantrubber.co.uk/

There are also several American suppliers that specialise in 'tadpole seals & tapes' for the aviation sector, that might match the profile - PM me if you still struggle.

[dcollins103]

Not an offer of parts but just came across this image in my archives. Thought it may be of interest to you, David.

Hi Andy, Thanks for the scan of the image. PX388 is a Hornet F.3 that I hadn't managed to find an image for yet. This aircraft served with 65 Squadron RAF. Its days ended when it flew into the ground out of cloud, on a low level navex in Germany, circa 1950.

Also, Bruce, Phil, and Twin Otter, thanks for your suggestions of suppliers. I'll let you know how I get on.

[dcollins103]

The second canopy was cleaned at the weekend and test fitted onto the canopy rails. This one is pretty clear, even before polishing the accumulated 40 years worth of scratches! Out of the two I have, I will probably use this one.

[Peter]

Looking good David!

[dcollins103]

I have made a little more progress on the windscreen frame parts.

The following photos show the top casting pattern, and three pieces of the lower patterns, that provide the joint between the glass and the fuselage woodwork.

There is still plenty of work to do on these lower patterns, including adding some flanges, splicing the 3 main sections together, and finishing off all the fillet radii.

[QldSpitty]

Amazing work mate.Hate woodwork,the sinuses hate the sawdust.Probably safe we are trying RapidPrototyping in resin for our masters...ACHOOOOOOOOOO!!!

[Cees Broere]

Good work Dave,

The windscreen is coming along fine,

Cheers

Cees

[Peter]

David, when will you be completing the exterior finish on the Fuselage?

[dcollins103]

.... and here is the complete assembly!

[12jaguar]

A deserved well done DC, the addition of the framing really adds to the 'feel' of the cockpit, another major milestone!

[dcollins103]

Hi Peter, Cees

Thanks for your continued interest.

For exterior finish, it will be covered with doped linen as per the original specification. It will be a shame to cover the woodwork up, but this should provide it with better protection long term.

Before I can do this, there is another +4ft of woodwork to add to the rear of the cockpit, that will support the rear of the canopy rails, and fully enclose the cockpit area. Under this the forward part of the main spar centre section will be located.