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Byron/Iron Bay F4U Corsair build - 12/9/2012 1:29 AM   
warbird_1



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From: perry, NY, USA
Status: offline 		I started working on this in September but had to back burner it to get a home project done. After i got started on it i found many parts missing and crappy workmanship on some things that i was able to fix myself. I'm really disappointed in the quality of this kit as far as missing parts etc. i drove all the way down to WV pick this plane up personally just to prevent damage from shipping only to find the fuse workmanship was totally unacceptable. i did look at it before i left ,but was tired and wanted to head home so i didn't look at like i should have. lucky for me the following 3 weeks later i had to go to NC for my nephew's wedding so i exchanged it on the way down. ok.... Here's the kit as i put it on the bench for the first time. i'm using robart wheels and gear , if you have any cool ideas you'd like to share ,do so by all means WB_1

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:38 AM   
warbird_1



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Status: offline 		here we have the spar and gear rails being fitted. i opted to replace the factory rails with wider ones because of the clearance grooves needed to make the gear much easier to remove . i was concerned about them being to weak after i grooved them to where they needed to be. byron wanted the gear built into the plane and not serviceable . i have many hours playing with the rails to get them just right . Partly because i'm hoping to add gear doors . the wing is thin and i'm not sure if i'm going to be able to make them work.

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:40 AM   
Ram-bro


 

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Status: offline 		so was the issue with the construction or with the manufacturer? How much detail are you planning on doing ?

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:44 AM   
warbird_1



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Status: offline 		the first pic is when i cut the gear door from the fuse. i didn't follow the panel lines because i'm making the gear removable and i'll be cutting the tabs from the door and adding mounting tabs to the pieces. the next pic is of the access hatch after being fitted. and the last two are of formers f-1 and f-2 being prepped for glassing.

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:47 AM   
warbird_1



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Status: offline 		here's the cowl mounting brackets being fitted along with the cowl

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:49 AM   
warbird_1



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Status: offline 		power plant... new g-62 with a byron straight mount

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:52 AM   
warbird_1



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Status: offline 		here she is sitting pretty on her feet. i was going to use the dummy engine you see but i had clearance issues that i just get away from so i had to scrap the dummy engine idea. that sucked !

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:57 AM   
warbird_1



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Status: offline 		next i had to work on fitting the exhaust from the great guys at jtech. the stock muffler hung to low and i couldn't get it in the cowl. i hate hacking up a cowl to get a muffler to fit. so i worked out where it need to be and i sent it back and Jtech made the mods for free!

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:01 AM   
warbird_1



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Status: offline 		here you can see the fitting process . The exhaust was one of the bigger challenges thus far .

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:06 AM   
warbird_1



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Status: offline 		after getting the exhaust the way i wanted i decided to rebuild the area where i had relieved in order to the the pipes to fit. i had to as the lover cowl mounting bracket need to be supported better.

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:09 AM   
warbird_1



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Status: offline 		here's a couple of shots after the carb and plug reliefs where done

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:12 AM   
warbird_1



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Status: offline 		here's the radiator inlets. i'm still looking for some screen to make the actual radiators so they aren't quite done .

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:15 AM   
warbird_1



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Status: offline 		here i'm installing the servo mounts . i added the extra material so the servo screws had something to bite into . the pads are 1/8 5-ply

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:21 AM   
warbird_1



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Status: offline 		mostly from the manufacturer. just isn't as good as byron was. i ordered a replacement canopy for my at-6 and it was so thin i sent it back and told them i wasn't going to use it and to either send me a better one or refund my money. when i bought the corsair kit they gave me the wrong canopy for that so i sent them both back at the same time on my dime or about 15.00 . i was supposed to get a sliding canopy i got the static one . gezzz


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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:25 AM   
warbird_1



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Status: offline 		here i'm working on the tail wheel mount . i know the rudder post/tail wheel former doesn't look straight but it's right on lol

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:36 AM   
warbird_1



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Status: offline 		this is where i am as of tonight . i'm getting ready to start on building /fitting the wing panels / the pic with the piece of ply taped to it was part of what i was talking about . poor workmanship. the spar slot looked like it was cut by a third grader with a dull hacksaw . lucky for me the slot was way to narrow so i squared of the line and use the piece of ply to hold the line while i recut the slot . it turned out good. spar fits nice now.

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:38 AM   
warbird_1



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Status: offline 		Ill be progressing slowly so check back for updates .

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 2:53 AM   
BobH


 

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Status: offline 		You would be wise to reinforce the spar where its cut out for the Gear strut. Others have failed exactly at that point..

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 3:47 AM   
Check6


 

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Status: offline 		Hey Ron,
Looking great!! I'm ready to buy when finished.
Later,
Fred

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 12:43 PM   
warbird_1



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quote:

ORIGINAL: BobH

You would be wise to reinforce the spar where its cut out for the Gear strut. Others have failed exactly at that point..

bob , i haven't heard of any failures there. good to know. i already put a 1/6 5-ply reinforcement ply doubler there just for good measure. i guess a lot of factors can come into play there like how deep the person cut the groove. was it rounded on the bottom , did they pull up way to hard etc. i'd be interested in hearing more about the failures if you have first hand knowledge . thanks for the tip. WB_1

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 12:45 PM   
warbird_1



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quote:

ORIGINAL: Check6

Hey Ron,
Looking great!! I'm ready to buy when finished.
Later,
Fred

LOL fred, not a chance buddy . i'm building this one to keep . :-)

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 12:52 PM   
samparfitt


 

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Status: offline 		I agree with Bob on re-enforcing the spar.
I'd epoxy ply on both sides of the spar (total 3 layers) as I had a Byron hellcat and the wing broke off due to the metal spar breaking free of that lone ply (bought the plane already built). Needless to say, I have failed every time to successfully land a plane with only half a wing (but I keep flying her until every part stops moving!), resulting in total destruction of plane and engine (except for that one wing that came floating down by itself!).
As for kit quality, Byron was way ahead at the time, but you're now talking about 30+ year old technology!
I found some pictures:

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 12:52 PM   
Alain RONK



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Status: offline 		 Hello !

Your construction Wonderful ! 

Best regards !
Alain 
My website : www.modelisme-racer.fr




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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:03 PM   
warbird_1



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quote:

ORIGINAL: samparfitt

I agree with Bob on re-enforcing the spar.
I'd epoxy ply on both sides of the spar (total 3 layers) as I had a Byron hellcat and the wing broke off due to the metal spar breaking free of that lone ply (bought the plane already built).

sam i was thinking about that last night. i had one of these before and i put it though it's paces. when you say you bought it built , had it ever flown. where i'm going with this is ... like i said before , i've never heard of any byron planes having problems with wing.spar failures. i was wondering if had it flown. a possible wing strike during a hard land could have cracked something. that's kinda why i don't buy used ,pre built planes. lol i don't trust anyone. so your saying the wing spar in the plane broke completely apart at the gear strut notch and ripped the spar clamp right out ?

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RE: Byron/Iron Bay F4U Corsair build - 12/9/2012 1:11 PM   
samparfitt


 

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Status: offline 		If I remember correctly, I don't think it was ever flown and I don't remember having any bad landings as hellcats are pretty easy flyers. I also didn't like the gear not being removable. Like you, I no longer buy already built planes (that way, I can only blame 'dump thumbs'!).
I just added pictures to my previous post so you can see where the spar came out.

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