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Wooden Aircraft Construction in Perfection
The construction process follows the builder’s growing experience. The work begins with the vertical stabiliser, which serves as a learning piece. Next comes the fuselage, where the skills acquired are further refined, before the wing is crafted as the masterpiece. Ancillary components like the landing gear, control surfaces, and fuel tank are integrated into the process concurrently
Foundation of the project: Original plans
For the construction of this aircraft, around 850 original construction plans from various archives were gathered. Each of these drawings, ranging from A4 size to large-format canvases, is a handcrafted work of art. Based on these templates, all the parts are digitally recreated in CAD, allowing the aircraft to come together step by step on the screen.
Precision in wood
The wooden structure requires carpentry work to perfection. The raw materials, predominantly Sitka spruce and plywood, must meet the uncompromising standards of aircraft construction. These materials are sourced in top quality from sitkaspruce.nl.
Metal components: Mechanical precision
In addition to the wooden structure, the aircraft consists of numerous metal parts that need to be milled, bent, welded, drilled, and filed. Thanks to my training as a mechanical technician and my certification as an aircraft welder, I can carry out many of these tasks myself. For particularly complex components that require 5-axis machining, I rely on specialised companies that take on these jobs at very reasonable rates. Historical material specifications are translated into modern standards, and the metals used meet or exceed all requirements.
Secondary structure made from composite materials
Some components of the secondary structure, such as the nose cone, tail fairing, landing gear doors, and cockpit floor, are made from modern composite materials. This decision is aimed at reducing weight and simplifying the manufacturing process. Although a mould must be made for each part, which limits the time savings, the quality achieved exceeds that of the original.
Support from experts
As with every aircraft construction project in Switzerland, this one is also supported by the Experimental Aircraft Association Switzerland (EAS). Highly qualified professionals provide advice and assistance, conduct regular build inspections, and play a key role in the success of the project.