CNN Airs Report on Columbine II – May 3, 2015
The team is making steady progress on a difficult project in a difficult environment and hopefully a positive decision will forthcoming shortly. The team, led by Brian Miklos, is composed of Dynamic Aviation employees and folks from the Mid America Flight Museum with valuable assistance provided by Marana Airport neighbor Bill Muszala and ATW Aviation. Check out the latest status report on the project website for additional information and updates.
With the recent news (See April 13 and 14 reports below) regarding the sale of “Baatan” and the decision by Lufthansa to base their Starliner in the United States, there could very well be three airworthy Constellations based and flying in the US next year. We’ve had a Constellation “drought” since the MATS Connie departed for South Korea in April 2005 and the return of three aircraft to the skies is almost too good to be true!
On May 1st CNN aired an interesting 3½ minute report on Columbine II, which included segments with Tim Crowley, Harry Oliver and Karl Stoltzfus.
Royal Air Morac Constellation Back in the Sunshine – April 30, 2015
Volker Schreiner recently forwarded a Google Earth image showing that Royal Air Morac Constellation CN-CCN is back outside after a period of being stored in a hangar at Anfa Airport, Casablanca, Morocco. For any of you who might be contemplating a visit to Casablanca, he suggests the best time to photograph the airplane appears to be in the morning.
Chanute Air Museum to Close – April 29, 2015
As reported on the IllinoisHomePage.net website, the Chanute Air Museum will be closing its doors on December 30, 2015. The museum opened in 1994, a year after Chanute AFB was closed and for many years had received a rent and utility subsidy from the Village of Rantoul. The village recently informed the museum that it could no longer afford the subsidy, which led to the April 23rd announcement. The museum is home to a number of interesting military propliners including EC-121K BuNo 141311, C-97G 52-0898, VC-47D 43-49336 and C-133A 56-2009. The future for these aircraft is somewhat tenuous since it is very expensive to disassemble and move large aircraft. For additional information about the museum, check out their website at www.aeromuseum.org.
Dynamic Aviation Announces Decision to Purchase VC-121A “Columbine II” – April 24, 2015
Ken Stoltzfus announced today that Dynamic Aviation will be purchasing VC-121A ”Columbine II” after completion of an extensive six week pre-buy evaluation of the aircraft. The sale will be finalized in June with the aircraft ferried to company headquarters in Bridgewater, Virginia for complete restoration. The following announcement was released today.
Dynamic Aviation of Bridgewater, VA has decided to proceed with the purchase of President Dwight D. Eisenhower's presidential aircraft, Columbine II. The 1948 Lockheed C-121A Constellation was the first presidential airplane to be called "Air Force One."
Karl. D. Stoltzfus Sr., founder of Dynamic Aviation and the drive behind the restoration project, says, "After extensive inspection and repairs on the aircraft we are ready to accept it, and to proceed with closing in June. Many challenges remain before we can fly it to Virginia but we are now confident that it is feasible."
Stoltzfus' interest lies in his desire to preserve Columbine II as a symbol of America's integrity and that of our leaders in that era. Plans are to fly it to Bridgewater, VA for restoration and to then operate it on the air show circuit. Some very ambitious plans to take Columbine II to major anniversary celebrations for events of the 1940's and 1950's are under consideration.
Stoltzfus says, "People thank me for leading Dynamic in the preservation of this national treasure. However, the real credit goes to Harry Oliver and Lockie Christler, its present owners, who saw its value back in the 1990's and did major work on it at that time. Without their dedication and their efforts to preserve it, it would most likely have been melted down long ago."
He continues, "While Dynamic is heading up this project, it could certainly only happen with the generous participation of others. Among them is Scott Glover and his Mid America Flight Museum of Mt. Pleasant, TX. They have played a key role to this point and are dedicated to the completion of the effort. Glover and his team have provided many hours of skilled labor and support in various ways."
No date has been set for the flight to Virginia. Present hopes are to have the aircraft fully airworthy and to fly it home as a certificated aircraft rather than on a ferry permit, which obviously extends the time needed to prepare it for flight. Periodic updates on Columbine II may be seen at www.john2031.com/columbine/main.html.
Dynamic Aviation, Columbine II Communications Coordinator
April has been a very good month for Constellation enthusiasts in the United States. Lewis Air Legends announced earlier in the month that they had acquired VC-121A "Bataan" with the intent of restoring the aircraft and flying it on the airshow circuit. If both plans come to fruition, we could very well see two VC-121A's flying in the US in the very near future!
CORRECTION - Lufthansa Starliner Report on Germany.info Website in Error – April 20, 2015
On April 14th this website reported that Starliner N7316C, currently being restored by Lufthansa Technik in Auburn, Maine, would be based in the United States. This was based on a report published on the Germany.info website on March 23, 2015, quoting remarks made by German ambassador Peter Wittig at a dinner honoring Lufthansa Airlines. The second paragraph of the report was changed today to read “Once it is fully restored, it will be piloted by a Lufthansa crew and fly across the US, Germany and the rest of the world. “The Starliner will then serve as an ambassador of Lufthansa for pleasure flights,” said Ambassador Peter Wittig at a dinner honoring the German company.”
No Decision Yet on the Sale of “Columbine II” – April 15, 2015 (April 16 update)
Work continues on the extensive effort at Marana Regional Airport to evaluate the feasibility of returning VC-121A ”Columbine II” to her former glory. While much progress has been made, a number of challenges remain including AD compliance, engines, propellers, hydraulic systems and brakes. Three of the four engines have been run at low power settings, but fuel system problems have prevented the #4 engine from being run. A number of engine components have been sent out for overhaul including fuel master controls, fuel injector pumps, engine driven fuel pumps and fuel flow transmitters. All flex hoses have been replaced with new fire-sleeved hoses. Work continues on the hydraulic system but the Constellation has lots of hydraulic systems and a hydraulic mule is needed. One of the four brakes has been serviced and the remaining three have been evaluated but brakes and brake parts are going to be a problem. The team is currently scouring the world for Goodyear brake parts. Whoever absconded with one of the lower engine cowlings has yet to see fit to return it and the team is still searching for exhaust systems and other engine components for R3350-75 and R3350-749C-18BD-1 engines.
(April 16 Update: Work is temporarily on hold until the engine components sent out for overhaul have been returned.)
Lufthansa Starliner to Remain in US - April 14, 2015
The Germany.info website website reported on March 23, 2015 that Starliner N7316C, currently being restored by Lufthansa Technik in Auburn, Maine, will remain in the United States after restoration is completed later this year. The website reports that the announcement was made by German Ambassador Peter Wittig at a dinner honoring the airline. "The Starliner will serve as an ambassador of Lufthansa for pleasure flights -- not in Europe, but in the US, where the Starliner will remain." As of today, Lufthansa Technik has not confirmed this report on their news page. If true, this is an amazing development and, while US propliner enthusiasts will undoubtedly be thrilled, the same cannot be said for their European brethren.
VC-121A "Bataan" Sold to Lewis Air Legends - April 13, 2015
The Planes of Fame Air Museum issued a press release today announcing that it had sold VC-121A 48-613/N422NA to Lewis Air Legends of San Antonio, Texas. The aircraft was General Douglas MacArthur's personal aircraft for six months during the Korean War. After a complete restoration was completed in late 1994, the aircraft was flown to the museum's annex in Valle, AZ for static display. The press release states that Lewis Air Legends plans on making the aircraft airworthy and flying it on the airshow circuit. This is very exciting news and I look forward to the possibility of seeing not only this aircraft on the airshow circuit, but also VC-121A "Columbine II" which is currently being evaluated for sale.
Disassembly of C-121J N4247K Continues in Manila – April 7, 2015
The Qantas Founders Museum issued a media release today regarding the latest status of their project to disassemble and prepare C-121J N4247K for shipment to the museum's home in Longreach, Australia. This process began in November 2014 when a crew from the Qantas Airways Engineering Aircraft Recovery Team visited Manila to extricate the aircraft from its muddy bonds. As reported on this website on March 25th, a team consisting of former Qantas mechanics, museum volunteers and local mechanics/volunteers have being working to disassemble the aircraft. To date the engines/props, empennage, wings and landing gear have been removed. In the near future, the disassembled aircraft will be moved to a storage area to await shipment to Australia. The first two photos are dated March 19th and the third dated March 26th.
Photo Page Added to Constellation Survivors Website – March 30, 2015
I’ve added a photo page to collect and share the photos folks send to me. The link is located right after “Constellation News Archives” on this website’s home page.
Yannich Barthe Films Releases SCFA Super Connie Short Film - March 27, 2015
Yannich Barthe Films recently released a short film titled "Super Constellation--The Film" starring SCFA Super Connie HB-RSC. The 30-minute film, shot in 2013-14, features exclusive footage of maintenance operations; engine starts; takeoff and landings; air-to-air sequences; cockpit operations; and formation flying with Breitling Jet Team L-39's and Swiss Air Force PC-7's. The inflight sequences were filmed in both slow motion and real time, with the Alps footage being truly stunning. The film is offered via two DVD download options from the Vimeo website. A 48 hour streaming rental is available for $14.99 and the film can also be purchased outright for $29.99. Two trailers have been produced so that buyers can preview portions of the video before purchase: 2013 Trailer and 2014 Trailer For more information about the film, check out the Yannich Barthe Film website.
HB-RSC will celebrate her 60th birthday later this year and SCFA plans on commemorating the event by scheduling a special 70 minute sightseeing trip on June 20th. Routing will be Basle - Delémont – Biel – Neuchatel – Yverdon – Lac de Joux – Fleurier – Creux du Van – Le Locle – La Chaux de Fonds – Saignelégier – Porrentruy – Laufen – Basel.
Disassembly of C-121J Begins in Manila - March 25, 2015
Bob Bogash reports that disassembly has begun on C-121J N4247K in Manila. A crew from the Qantas Founders Museum, assisted by students from a local aviation training college, has been on site at MNL for about two weeks. To date, they have removed the engines, props, tail and outboard wing panels. Next on the agenda is the removal of the landing gear and wings. Bob, who spearheaded the Museum of Flight’s acquisition of Super Constellation CF-TGE, is advising the Australians along with technical support from Carlos Gomez and Stef Balis. Bob is awaiting promised photos, which will be posted on this website as soon as he forwards them to me.
Detailed Survey of "Columbine II" Underway at Marana Regional Airport - March 24, 2015
On March 6th I reported that Karl Stoltzfus and a 15 person team would be performing a detailed survey and inspection of VC-121A N9463/48-610 “Columbine II” at Marana Regional Airport. Instead of the one week effort I had reported, the survey is much more extensive and is not scheduled to be completed until the week of April 5th, when the engines will be run. Karl’s brother Ken posted a March 24th update on the project website summarizing progress to date. He also included a detailed status report compiled by team member Brian Miklos. As of the 24th, the team's effort has been focused on the engines, AD compliance and airframe inspection with no “show stoppers” uncovered.
In a March 22 email to Columbine II's owners Karl said "We have found the airframe to be in quite good condition with very little corrosion but with the normally expected things that you would find with an airplane that was parked outside and subjected to extreme heat. However the engines needed a lot more work than we expected before we feel comfortable to even run them. We determined very early that we were not going to run them until we had carefully inspected them and made necessary repairs to give us the best potential to have successful engine runs and ferry. Before final acceptance we would like to make sure the engines run, and remove enough floor under the forward and aft potty area to inspect for corrosion as well as confirming AD compliance."
Scott Glover and a team from the Mid America Flight Museum rode into town the morning of March 10th in a gorgeous Lodestar and dove into the project with both feet. During the week they were at Marana, they played a crucial role in completing a number of critical work assignments and are scheduled to return the week of April 5th. Sure is nice having friends like them!
Also check out the warbirdsnews.com website for an interesting report about the project .
Propliner Magazine Ceases Publication with Issue #141 – March 16, 2015
Today Tony Merton Jones performed the familiar task of mailing out the latest issue of Propliner Magazine for the final time. Tony has been editor of Propliner since 1985, when he took over reins of the magazine after the tragic May 1984 death of Stephen Piercey. The final issue, #141, will be Tony's 120th at the helm. It’s been an amazing run and what makes it even more amazing is that it was all done by volunteers. The dedication of Tony and his small publication staff was remarkable considering the effort required to publish a magazine like Propliner every three months. The decision was not based on a lack of quality material being submitted by contributors but by falling subscriber numbers, soaring postage costs, the loss of the US distributor and other distribution issues. Unfortunately, time takes its toll and every year there are fewer and fewer propliner enthusiasts, with young aviation enthusiasts having no interest in these relics from a bygone era. For me it’s hard to remember when there wasn’t a Propliner Magazine and the news of its demise felt to me like the death of a family member. I’m grateful that I was able to be part of the experience and proud that Tony saw fit to publish 54 of my articles. Thank you very much for all you’ve done Tony, Propliner will be sorely missed.
Indian Naval Air Museum Super Connie Receives Facelift – March 12, 2015
Michael Tosta visited the Naval Air Museum at Dabolim, India in November 2014, where he photographed L1049G IN315 midway through a much needed cosmetic restoration. The contrast between the “painted” and the “yet to be painted” sections of the aircraft was dramatic and it’s good to see the old girl getting some attention. The aircraft served with Air Indian from 1955 to 1961, when it was transferred to the Indian Air Force. It was transferred to the Indian Navy in 1976 for maritime reconnaissance, replacing ancient B-24 bomber aircraft. Retired in 1983, it was stored at Dabolim until moved to the Naval Aviation Museum for display in 2000. Thanks much to Michael for sharing his photographs.
Columbine II Moves One Step Closer to Possible Sale - March 6, 2015
Karl Stoltzfus and a 15+ person team of mechanics and technicians from Dynamic Aviation and The Mid America Flight Museum will be at Marana Regional Airport next week to perform a detailed survey of VC-121A N9463/48-610 “Columbine II”. Engine runs will be performed and, at the end of the week, a final decision on whether or not to move forward with the purchase of the aircraft will be made. Here’s a link to the project website with some additional information. I'm keeping my fingers crossed that all goes well next and this historic airplane move to a new chapter in her life. I will pass along updates as I receive them.
Super Connie Appears in Forgettable 1977 Moonshiner Movie - March 1, 2015
While not about a "survivor" and thus slightly off-topic, I decided to include this piece since I thought it would be of interest to most readers. I recently received an email from Duane Hester asking if I’d seen the 1977 movie “Thunder and Lightning,” which featured Super Constellation CS-TLB in a supporting role. The movie, starring David Carradine and Kate Jackson, is about competing moonshiners and would be totally forgettable if not for the fact that it included some brief clips of the former TAP L1049G. After being retired by TAP in July 1967, CF-TLB was sold to Miami aircraft dealer International Aerodyne, where it was used for spares until being disassembled and mounted atop a restaurant near Naples, Florida in about 1971. Unfortunately, the aircraft was scrapped in early 1978 but it lives on in the movie, which can be viewed on YouTube. The Super Connie makes her brief appearances in the video at 1:19:11 and 1:21:16. For additional information about the aircraft, check the February 27, 2009 submission on this website's Q&A Forum.
Air Korea Starliner Photos from 1968 – February 28, 2015
Steve Miller recently emailed me two very interesting photos of Air Korea L1649A Starliner HL4003 taken on May 5, 1968 at Kimpo International Airport in Korea. Air Korea was a short lived Korean based airline that operated the Starliner on non-scheduled flights between Korea and South Vietnam from March 1967 to August 1968. While the Starliner was scrapped many years ago, its image is preserved in the form of former VC-121A/L749A MATS Connie N494TW, which is on display at the Korean Air maintenance base at Jeju Island in Air Korea colors with HL4003 registration markings. The first two photos are of the Starliner and the last of N494TW. Many thanks to Steve for providing the two photos and the many other vintage photos he posts via the Classic-Propliners Yahoo Group.
Fox News Airs Piece on "Columbine II" – February 18, 2015
Tim Crowley seems to finally be getting some traction in his quest to publicize the plight of VC-121A 48-610/N9463 “Columbine II”. On February 16th (Presidents Day) Fox News aired a short news piece on the aircraft and the need for this unique and historic aircraft to find a new home. CNN is also working on a news story to be aired in the not too distant future. It’s great to see that the aircraft is finally getting some recognition. It’s a shame that the bureaucrats at the National Museum of the USAF haven’t shown any interest in acquiring "Columbine II" for their presidential aircraft collection. What makes this even more puzzling is the fact that they are currently building a new wing for the collection at Wright Patterson AFB.
Kermit Weeks Produced Video of Starliner N974R Final Flight – February 12, 2015
I was surfing the internet the other day and found a very interesting YouTube video about the ferry flight of Starliner N974R from Sanford, Florida to Fantasy of Flight on October 19, 2001 that was produced by Kermit Weeks. The 10 minute 39 second video starts out with a short history of the Lockheed Constellation followed by video of flight preparations, the takeoff from Sanford International Airport, air-to-air footage and finally the landing on Fantasy of Flight’s 5,000 foot turf runway. I was at Sanford for the departure and it was quite a thrill to see the old girl take to the air one last time. I also remember Kermit's folks taking alot of video and, up until now, wondered if any of it ever got published. I'm glad to see that some of it did.
"Columbine II" Could Be Heading to New Home – February 7, 2015
Mel Christler’s grandson, Tim Crowley, has been spearheading the effort to find a permanent home for VC-121A 48-610/N9463 “Columbine II” and his efforts appear to finally be bearing some fruit. The aircraft served as Dwight Eisenhower’s first presidential aircraft and is the only primary presidential aircraft not preserved in a museum. The aircraft owners and Karl D. Stoltzfus, Sr. signed a formal “due diligence” agreement in late January 2015, which allows Karl 90 days to evaluate the aircraft’s condition and the feasibility of performing a ferry flight to Bridgewater Air Park (VBW) in Virginia. Karl is the owner of Dynamic Aviation, which has operated DC-3 and more recently King Air aircraft out of company headquarters at VBW. A two-day preliminary inspection of the aircraft was performed in November 2014 and it was found to be in good condition with minimal corrosion. The engines were run in 2014 and, while the Curtis Electric props appear to be in good condition, they will probably have to be x-rayed prior to any flight.
Karl is currently undertaking a worldwide search for critical parts and technical help to restore the aircraft. He’s reaching out to all his contacts for leads on L749A Constellation parts plus contact information on mechanics with the skills that will be useful in preparing the aircraft for a ferry flight. Locating the following parts is critical to the project moving forward:
Lower Engine Cowling. Cowlings were removed from the #1 and #4 engines a number of years ago and apparently someone decided one of them would make a nice souvenir. The cowling is crucial to a ferry flight and it would be a shame if the aircraft was left behind at the airport and scrapped due to a missing cowling. Hopefully a cowling can be found or the missing cowling returned.
17:00-20 main wheels
Six-puck Goodyear single disk brakes
Civilian R3350-749C18BD or military R3350-75 engines
The final decision on the purchase is dependent on the success of this search followed by the successful completion of a comprehensive pre-buy inspection. If the decision is made to move forward with the project, the first phase will be to make the aircraft airworthy for a ferry flight from Marana, AZ to Bridgewater, VA. The ultimate goal is to return the aircraft to fully airworthy status and participate in the airshow circuit. This decision will be made once the aircraft has arrived in Virginia. Karl plans to launch a small museum at Bridgewater Air Park, which will include a hangar for Columbine II and his aircraft collection, which includes a beautifully restorted C-47, a T-6G, Stearman and Beech 18. He is deeply committed to Columbine II as a matter of principle because of his sense of the need to communicate “heritage” to the younger generations.
Karl’s brother Ken is the project's communication coordinator and can be contacted via email. For more information, check out the project website. The website also contains a nice collection of current photographs.
Museum of Flight Super Constellation Moved to Make Way for Construction of New Exhibit Hall – February 3, 2015
The Museum of Flight moved Super Constellation CF-TGE on Saturday January 31st from the museum’s Air Park to the berm behind the museum. The Super Connie was positioned next to the museum’s B-47 51-7066, taking the place of B-17 NL17W/42-29782 which had previously been on display at this location. According to Bob Bogash, the Super Connie was one of four aircraft moved from the Air Park location to make room for the start of construction of a new covered Air Park, which should be completed in about two years. Check out Bob’s website for a full report on the move.
Interesting Photos Received from Website Visitors – January 23, 2015
I recently received some interesting photos from website visitors. The first set was from well-known aviation photographer Ron Mak and included photos of C-121J N4247K taken at Arlington, WA back in June 1986 before the aircraft departed on its ill-fated mission across the Pacific. Check out the cockpit and cabin photos and compare them to current photos. Hopefully it won’t be too long before the aircraft is out of Manila and on its way to Australia for restoration by the Qantas Founders Museum.
The second set of photos are of 48-610/N9463 “Columbine II” taken at Andrews AFB in May 1991 by John Benton. The aircraft had recently been restored by Mel Christler and Harry Oliver and was on display at the base’s annual open house. John was stationed at Naval Air Facility Washington at the time and managed to hang around after the show was over. He was rewarded with a ride in Columbine II when the crew taxied her over to the tower for some "official" photo ops. I had recently moved to Maryland and made an unplanned quick visit to the show where I was pleasantly surprised to see this historic aircraft on display. Unlike John, I didn’t have my camera with that day and wasn’t able to capture that very unique moment in time.
The third set of photos are of the "Breitling Connie" HB-RSC taken at RIAT-Fairford in July 2013 by Peter Fothergill. This aircraft is the most photographed Constellation of all time and hopefully she will remain active on the European airshow circuit for many years to come.
Last, but not least, is an interesting photo of one of the engines from L1049G 121J 5T-TAF taken by Eskender Ganiev in October 2014 and forwarded to me by Stipe Zivaljic. The Biafran Airlift veteran was used as a restaurant from the mid-70's to mid-80's in Kirkop, Malta before it was adandoned and finally burned by vandals on January 30, 1997. Its remains, including the wings, undercarriage and engines, were acquired by the Malta Aviation Museum Foundation.
Lufthansa Starliner Restoration Project Update – January 2, 2015
Happy New Year to everyone! Back on October 3rd I promised a report on my visit to the Lufthansa Technik hangar in Auburn and, while it took a bit longer than I anticipated, I hope it's worth the wait....
It had been a year since my 2013 visit to Auburn-Lewiston Airport (KLEW), where Lufthansa Technik is in the final phase of an incredible 6+ year restoration of Starliner N7316C. Having received approval from Lufthansa Technik North America for a October 1, 2014 visit, I arrived at the Lufthansa Technik hangar with fellow Constellation enthusiast Pete Ferraro. In order to keep work disruptions to a minimum, visits to the hangar now require prior approval. A “no-photography” policy has also been implemented at the hangar so no current photographs will be included in this update. There have been a number of management changes during the past year and we were greeted by Heiko Schroth, who joined the project in June 2014. Heiko is responsible for operational support/procurement and he and production manager Eddy Weber manage day-to-day operations. Andreas Pakszies assumed overall management of the project in early 2014 and all three men are veteran Lufthansa Technik employees with many years of experience in their respective fields.
Deutsche Lufthansa Berlin-Stiftung acquired N7316C, along with Starliners N8083H and N974R in December 2007 and, while N7316C hadn’t been operated by Lufthansa, it was judged to be in the best condition and thus the best candidate for restoration. Lufthansa’s ambitious goal of restoring N7316C to strict current airline standards considerably increased the scope and complexity of the project and it’s safe to say that a static display restoration would have been completed years ago. When the restoration is complete, the aircraft will receive a standard airworthiness certificate with no restrictions and will be certified to carry passengers.
It didn’t take very long to realize that the project had kicked into high gear, with the hangar a beehive of organized activity. Heiko said that 120 employees were working on site with a goal of increasing that number to 140. The operation runs seven days a week with two 12-hour shifts Monday through Friday and a single 12-hour shift on weekends. Sheet metal and structural mechanics are in high demand and have been actively recruited to supplement the current 70 man mechanic workforce. Standards are very high and once a prospective candidate arrives, they are given a practical test before being allowed to join the project. The workforce is truly international with mechanics from Shannon Aerospace in Ireland and Lufthansa Technik facilities in Budapest, Hamburg, Frankfurt and Manila. These folks were recruited because of their specialized skills, which have proven to be invaluable. In addition to the journeymen workforce, twelve apprentice mechanics from Lufthansa Technik in Hamburg rotate through on four to six week assignments.
Parts management is a critical function of any production program and Lufthansa Technik was faced with some unique and challenging problems. In addition to the enormous amount of parts involved, there were quite a few parts using materials from the 1950's that were either no longer available or no longer suitable for use. Magnesium and asbestos parts are just two examples. Since only 44 Starliners were built by Lockheed and the last one was built 55 years ago, many parts are very scarce and hard to come by. One example is passenger windows, which were found only after an exhaustive worldwide search. Other parts were not available and had to be manufactured using original Lockheed drawings. There are also parts that couldn’t be manufactured using these drawings because materials weren’t available and new drawings had to be created and approved before replacement parts could be manufactured. Some original drawings were not detailed enough and the production team resorted to using N8083H as a template. An example is the hydraulic tubing, which was removed from N7316C at the start of the project. Using tubing from N8083H as a pattern, 1,500 pieces were fabricated in Hamburg with the remaining pieces now being fabricated in-house. This was done to save time and is led by a retired aircraft tubing expert with assistance from a group of very capable German apprentices. Another source of help has been the German military, which flies the P-3 Orion. The P-3 was first flown in 1959 and a number of parts are very similar to the Starliner.
Material planning, parts inspection, NDT, painting, heat treating, storage and parts kitting are performed in nearby Building 2, thus freeing up hangar space for production activity. A number of these functions were brought in-house to reduce lead times including heat treatment. Heat treatment lead time was reduced from 6 week to 24 hours by doing the work in-house. Used parts are inspected in Building 2 and a determination is made on whether they can be used as is, refurbished or need to be scrapped. Material planning and inventory management has been computerized and the system was being used during our visit to kit parts for the production effort. In addition to the in-house staff, the project team has utilized retired Lockheed production planners that are very familiar with Lockheed processes and procedures. While none worked at Lockheed during the Constellation production era, their knowledge and insight have proved very helpful to the project.
While the aircraft was still supported in cradles and surrounded by scaffolding, significant progress had been made since my last visit, with sheet metal and structural work nearing completion. One of the remaining items to be completed is the keel and beam assembly, which was being worked on by a group of Lufthansa Technik mechanics from Hamburg and Frankfurt. Once this is finished, the three center section fuel tanks can be completed and pressure tested. The structural modifications required to accommodate the front and rear passenger doors have been completed and the doors are ready for installation. A significant milestone was achieved this year with the successful pressure testing of the four wing fuel tanks. Reassembly of the wing has begun and, when completed, will include newly manufactured deicer boots. The tail structure is being rebuilt in Auburn by a group of Lufthansa Technik sheet metal mechanics from Manila. Heiko estimates that at project completion, 85% of the original structure and sheet metal will have been replaced.
The landing gear assemblies were refurbished at the Lufthansa Technik facility in Hamburg and illustrate just one of the many unanticipated challenges encountered during the restoration. A detailed inspection by the Hamburg technical staff determined that the landing gear assemblies were in much worse condition that originally thought. Adding to the problem were incomplete or missing drawings in repair manuals and the need to replace materials that were no longer available or suitable for use. Including brake and hydraulic components, the landing gear assemblies required over 80 special repair procedures. New landing gear brackets were required and they will be milled rather than forged. Drawings were prepared and plastic parts for fit checks were created using a 3D printer. With fit checks confirming the design, the new landing gear brackets can be manufactured with a high degree of confidence.
Four R3350 engines have been overhauled by Anderson Airmotive, with the spare 5th and 6th engines to follow. Four of eight propellers have been refurbished at Hope Aero in Toronto, Canada as have all of the spinners. When propellers are refurbished, metal is removed and the remaining four propellers are near the limits of what can be removed. Lufthansa Technik is currently in discussions with the South African Airways Museum to exchange these propellers for those that had been installed on the museum’s static display Starliner ZS-DVJ. Previously the museum allowed the use of the passenger doors from their Starliner in exchange for two non-airworthy doors, so hopefully a deal can be struck.
The cockpit will receive a total makeover to bring it into compliance with current standards and requirements. Honeywell has adapted their C-130J glass cockpit, which includes state-of-the art displays for both the captain and first officer. The overhead panels have been completely redesigned and modern radios, including a TCAS, will be incorporated. Constellations were different from their Douglas counterparts in that they had a dedicated flight engineer position and instrument panel. The existing flight engineer panel will be refurbished and used for flight certification testing in the United States. Once testing is complete, the project will enter Phase II when a redesigned panel will be installed. As with the original pilot instrument panels, the flight engineer panel was arranged in an illogical manner with system components spread across the panel. In a joint effort between Deutsche Lufthansa Berlin-Stiftung (DLBS) and Lufthansa Technik, a new panel was designed in accordance with current design standards. While instruments on the new panel will be located in different positions, they will perform the same functions as before. One change will be the incorporation of a new engine graphic monitoring panel, which will visually display multiple exhaust gas and cylinder head temperatures. The current gauge only displays these parameters for one cylinder at a time and the multi-cylinder display will allow the flight engineer to better monitor engine performance and spot individual cylinder deviations much easier.
The passenger cabin will be installed in Maine during Phase 2 and will include 44 A300 business class seats that are being refurbished in California. Three fuselage mockups have been built in Hamburg and second and third year apprentices are fabricating interior components. To reduce costs and save time, B737 and A320 cabin components are being adapted for use, including overhead baggage racks, passenger service units, air ducts, passenger oxygen units, toilets and the front galley. Once completed they will be temporarily installed in the mockups allowing fit checks to be performed and also providing the cabin design staff a realistic look at the completed cabin. This approach allows production of these components in parallel with the work being performed in Maine and minimizing issues when it’s time to install the cabin interior in the aircraft.
The two other Starliners have also played an important role in the restoration of N7316C. Before being donated to Fantasy of Flight in Polk City, Florida, many useful components were removed from N974R for use on the project. Made externally complete, the aircraft was on display at the museum until it recently closed its doors to the public. The aircraft appears to be safe for the time being as the restoration facility is still open and Kermit Weeks plans on reinventing the facility as an aviation theme park. N8083H is parked next to the restoration hangar and, in addition to providing many useful parts, it has served as an extremely useful reference point during the restoration. I asked Heiko about the plans for N8083H and he said it still wasn't decided but that it wouldn't be scrapped.
Frank Sangers recently forwarded me a link to a 29 minute YouTube video of a publicity film made by Lufthansa in 1958. The professionally produced high quality film beautifully illustrates airport operations at Hamburg Airport and a family taking a flight on a Lufthansa Starliner from Hamburg to Chicago. Unfortunately, the narration is in German but the video is definitely still worth a viewing.
I’d like to thank Lufthansa Technik for allowing the visit and especially Heiko Schroth for taking the time out of his busy day to answer our many questions and for escorting us around the facility. I look forward to being in Auburn when the aircraft is rolled out in 2015. For additional current information about the project, check out the Deutsche Lufthansa Berlin-Stiftung website.