Patterns and Castings

It is not possible to find all the original metalwork for the aircraft and it might not be airworthy today.  We needed to make parts.  Not all can be welded so some must be cast in the appropriate metal.  This means making patterns so that the castings can be fabricated.  The wood patterns take hours and several operations to make.

The original windscreen was 5/32 triplex glass and the frame was cast aluminium made by Auster, model No. 9.  This model was used with an Aldis sight.The windscreen frame pattern has been made in wood ready for sand casting.  We tried 2x2mm laminated glass but it broke so it is now toughened .  The lettering has been made in plastic and inset.

The spade grip (click link for more information) sits at the top of the stick.  It should be cast aluminium and covered with rubber.  The tubes are hollow and wired for the gun firing controls and the blip switch for the magnetos.  



The gun triggers are aluminium.  There is one for each gun and they are 'handed' which means you have to make two.  They are fitted in the centre of the spade grip and connect to the guns by wires.  The triggers pivot on a block which sits in the column.  Again all have to be cast.

The Carb inlet casting work has started.  This is a large casting and again requires both an inner (right) and outer (left) pattern.  Where it sits in the cockpit can be seen on the far left, courtesy of David from the Brussels Museum.

Air admittance T 1.jpg (57942 bytes)

Air admittance T2.jpg (57699 bytes)

The throttle and mixture controls (click link for more information) are a complicated mix of brass and aluminium which requires casting, lathe work and milling.  Again works has started.  The picture comes courtesy of David from the Brussels Museum.

We have ended up making spade grips, gun triggers and windscreens for other enthusiasts and have started similarly to duplicate our original  Rotherham Pump (click link for more information).  Contact me if you are interested in buying our castings.