Iron bay/byron corsair project
12-01-2014, 09:44 AM
#1
Iron bay/byron corsair project
Back in 2008 I lost my Byron Corsair, one of my favorite plane to fly!
I couldn't resist so I purchased another one here on RCU, not sure if it is an original Byron or Iron Bay.
Here is a picture of the first one from which I was able to salvage the rudder, flaps, ailerons, engine (which had to be repaired), and most electronics.
Not sure if this second one will be painted the same, as now I'm tempted to change for the C version with the 20mm canons and finished in a glossy navy sea blue.
I couldn't resist so I purchased another one here on RCU, not sure if it is an original Byron or Iron Bay.
Here is a picture of the first one from which I was able to salvage the rudder, flaps, ailerons, engine (which had to be repaired), and most electronics.
Not sure if this second one will be painted the same, as now I'm tempted to change for the C version with the 20mm canons and finished in a glossy navy sea blue.
12-01-2014, 10:04 AM
#3
just like to add that some of the work was done during the past few years here and there, just decided to work on the this plane and get it ready for next season.
I originally got the gear used and after so many uses it was time to rebuild them. The gear were taken apart and all the pieces cleaned, I made new brass bushings for the rotating struts.
Before:
After: 
I originally got the gear used and after so many uses it was time to rebuild them. The gear were taken apart and all the pieces cleaned, I made new brass bushings for the rotating struts.
Before:
12-01-2014, 11:51 AM
#4
I was originally going to fiberglass the outer wing panels but since this is just a weekend flyer and no scale aircraft fabric is just fine.
Something I did differently from the instructions, I added a layer of carbon fiber between the foam wings and the balsa sheeting. Not really needed on this plane but I might use the gain of strength to do something similar on a Yellow Spitfire wing.
Something I did differently from the instructions, I added a layer of carbon fiber between the foam wings and the balsa sheeting. Not really needed on this plane but I might use the gain of strength to do something similar on a Yellow Spitfire wing.
Last edited by flyingchef; 12-01-2014 at 11:53 AM.
12-01-2014, 12:04 PM
#5
I had an old left over Super-Coverite roll which ended to be enough to cover both panels. The aluminum wing spars provided were to thin to my test so I machined new ones that fit nicely in the rail. Some micro balloon/epoxy mixture was used to fill the gaps between the fuselage and outboard wing panels.
12-22-2014, 02:39 PM
#15
The cowl mounting are done, I will add some fiberglass with polyester resin soon as the weather allows me to work in the garage. Couple of the hatches are done, I used some lightweight Aeropoxy to finish nicely the seat of the the hatches, the joints are nice and sharp now.
12-22-2014, 02:44 PM
#17
While waiting for the Aeropoxy to cure I setup the fuel tank lines. I use only a plunger and vent, to avoid the plunger to curve back on itself I solder a long piece of brass with the havier clunk I can find, it is then joined together by a short piece of tubing.
01-07-2015, 05:24 PM
#22
Almost done setting up the tail wheel retract assembly, just need to install some links for the gear doors.
I installed couple carbon fiber rods, one for the elevator and the other for the tail wheel retract. Pull pull cable are also setup for the steering.
The original abs air intakes didn't look to good, I removed them then went on making couple g10 laminated inserts. Once the plane is ready to paint I'll ad the detail.
I installed couple carbon fiber rods, one for the elevator and the other for the tail wheel retract. Pull pull cable are also setup for the steering.
The original abs air intakes didn't look to good, I removed them then went on making couple g10 laminated inserts. Once the plane is ready to paint I'll ad the detail.
Last edited by flyingchef; 01-07-2015 at 05:38 PM.
01-09-2015, 07:39 AM
#23
The air intakes are now ready to detail but I will get the plane in primer before.
I am starting to work on the canopy setup and cockpit.
I will be installing the sliding canopy version similar to what I did on the first Corsair.
I first frawn the outline and the rails location, I like the Byron sliding canopy,it is nice and thick beside I obtained back then couple backups in case I messed up.
Using brass I started with the rear rails by using 3/16 square brass tubing and 105mm long. The slot is 2.5mm wide cut in the mill stopping about 3mm from the end. The insert is 1/8 square tubing with a 2mm hex screw going through, the access to get the canopy mounted is done through a hole in the back of the rail.
I am starting to work on the canopy setup and cockpit.
I will be installing the sliding canopy version similar to what I did on the first Corsair.
I first frawn the outline and the rails location, I like the Byron sliding canopy,it is nice and thick beside I obtained back then couple backups in case I messed up.
Using brass I started with the rear rails by using 3/16 square brass tubing and 105mm long. The slot is 2.5mm wide cut in the mill stopping about 3mm from the end. The insert is 1/8 square tubing with a 2mm hex screw going through, the access to get the canopy mounted is done through a hole in the back of the rail.
