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Douglas DC-3 official build Pack 4 Options
delboy271155
#1 Posted : 21 September 2015 12:28:43

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DC3 Pack 4

Steps 1 – 14 Right Passenger Cabin and Baggage Rack

As you remove each piece from the wooden fret, gently sand any burr’s and laser ash, being careful not to change the profile shape.


Take the laser-cut plywood pieces for the right side of the passenger cabin. Using a craft knife, remove the pieces one at a time as they are required in the instructions. Sand the edges with fine sandpaper to make them smooth.

To begin the assembly, take the laser-cut plywood pieces for the right side of the passenger cabin. The assembly process, the pieces and their numbering are the same as those in Pack 3 for the left side. The assembly is a mirror image of the left side, so if you need any pointers you can refer to the assembled pieces for Pack 3. Remember only to remove and prepare one piece at a time, and only when it is required by the instructions.


To begin, fit and glue pieces 3A and 3B to piece 3F. Before gluing them in place, check that 3A and 3B are at right angles to 3F, Note: 3B must have the single holed end where it joins 3F as shown in the photo by the red arrow.


Continue with the assembly, fitting and gluing pieces 3G, 3I, 3J, 3L, 3M and 3O in turn.


Turn the whole assembly round, then fit and glue pieces 3C, 3D and 3E, and then pieces 3H, 3K and 3N in their places. If you need more detailed instructions, refer to Pack 3.


Now move on to assembling the other part of the right side of the cabin. Fit and glue pieces 4A and 4B into piece 4F, check with a set square that the angles are 90°. Note: 4B must have the single holed end where it joins 4F as shown in the photo by the red arrow.



Continue the assembly, positioning and gluing pieces 4G, 4I, 4J, 4L, 4M, 4O, 4P and 4R in place.


Turn the assembly round and complete it by fitting and gluing first pieces 4C, 4D and 4E in place, then pieces 4H, 4K, 4N and 4Q.


From the bamboo rod (supplied with Pack 2), cut four pegs 3mm long. Fit and then glue them in the holes on the front and back sides of the assembly (as shown by red arrows in step 8 of your instructions).


Using the pegs inserted in Step 8 as a guide, glue the assembly to the piece prepared in Step 4. Prepare the laser-cut plywood parts A1 and A2, which form the base of the wing, and glue them in place as shown. Note: Parts A1 and A2 must be orientated as shown in this official diary as there is a notation error in the instructions provided.


Position and glue the stringers along the inside and outside of the assembly – their positions are indicated by the red arrows in step 10 of your instructions. The stringers fit into the notches in the plywood pieces.


Do not put stringers in the rectangular areas indicated by the red dotted lines, as shown in step 11 of your instructions.


Apply modelling filler where necessary to fill gaps in the assembly and, when it is dry, paint it green.


Take the baggage rack for the right side of the cabin, piece CBAGD1, and paint it as you did the one for the left side (see Pack 3).


Fit and glue the piece you have just prepared to the structure from Step 12.

Save any unused parts in a bag labeled with the stage number for future use




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delboy271155
#2 Posted : 21 September 2015 13:21:35

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Steps 15 – 28 Right Cabin Internal and External Detail

Make the internal frames for the windows (each with two pieces F2 and two pieces F1). Go back to the instructions in Pack 3 for how to assemble, finish and paint the frame.


Referring again to the assembly guide in Pack 3 for the corresponding parts of the left side of the cabin, prepare and paint pieces G1 and G2.


Fit, but DO NOT glue, one window frame 4l in the position indicated – it will be used as a guide.


Using the position of the window to centre piece G2, fit and glue pieces G2 and G1 on the inside of the fuselage. Make sure the pieces fit the interior curve exactly.


Glue two stringers painted Aluminium above and below the window frames (shown by white arrows on the left) and one painted Mediterranean Blue on the join between the baggage rack and piece G2 (shown by the blue arrow, right).

Turn the assembly over and paint the area around the windows Mediterranean Blue. Complete the frames (Step 15) by sticking on a piece of acetate, then trim to the frame size.

Now fit and glue each window centring it over the openings of G2. The acetate must end up flush with the ribs (bottom inset picture step 20).


Complete the interior decoration by making the curtains (see Pack 3) and gluing them to the side of the windows.


Take the die-cast pieces shown in the photograph and with a file, carefully remove any imperfections from the die-cast pieces, being careful not to damage the lines of rivets. The pieces will be painted later.


Fit piece BA1D and check that it will be flush with the cladding to be fitted later, by using a piece of leftover aluminium, as shown in step 24. Then glue piece BA1D in place.


In the same way, fit and glue piece C1D.

Then fit pieces C2D and C3D in place, one after the other and make sure that each piece is exactly flush with the piece next to it, and will be flush with the external cladding to be fitted later.


Now cover the rest of the structure, following the same procedure as for the left side (Pack 3). Start by preparing and fitting piece A3R1.


Using step 28 as a parts guide, continue cladding the assembly. Bend each piece to give it the correct curvature, then test it in place on the fuselage and glue it in position. Start by covering the upper part with pieces A3R2, A3R3, A3R4, A3R5, A3R6, A3R7 and A3R8, then move on to the lower part and fit pieces A3R10, A3R11, A3R12, A3R13, A3R14 and A3R15. Finally fix pieces A3R9 and A3R16 in position.

Save any unused parts in a bag labeled with the stage number for future use


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delboy271155
#3 Posted : 21 September 2015 13:34:51

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Steps 29 – 44 Passenger Seats


With this pack and Pack 3, you will have been supplied with the pieces needed to assemble the passenger seats. For how to do this, refer to the instructions in Pack 2, Step 55 and following.


Start by preparing the twin passenger seats. From the photo-etched sheet shown, remove pieces C03 and C04 and glue them to the two pieces S18 and S19 (see photograph).


From the sheet of photo-etched metal parts, remove the pieces C05 and C06 and bend them into shape as shown with a pair of flat-nose pliers.


Follow the instructions in Pack 2 for assembling the seat, with two pieces of plastic rod VA (supplied with Pack 2) or two drill bits. Assemble the seats as shown.

Join the metal pieces with cyanoacrylate glue on all the points of contact.


Apply primer to the seat assembly and leave to dry.


With Aluminium colour, paint the underside of the twin seat assembly.


Now paint the internal faces of the seats brown. You can then assemble the remaining twin seat. Keep the pieces safe, as you will need them later.


To make the seven individual seats, take the photo-etched sheet shown in the photograph and the two pieces S18 and S19.


Remove pieces C03 and C04, and glue them onto pieces S18 and S19.


From the photo-etched sheet, remove piece C08 and use flat-nose pliers to bend the tabs as shown.


Using the instructions in Pack 2, take two pieces of plastic rod VA (supplied with Pack 2), or two drill bits, to assemble the seat as shown.


Once they are in position, fix the components together with cyanoacrylate glue.


Apply primer to the seat, then paint the underside of the seat Aluminium. Paint the internal faces of the seats brown.
Assemble and paint the other single seats you have and keep them safe, as you will need them later.

Save any unused parts in a bag labeled with the stage number for future use


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delboy271155
#4 Posted : 21 September 2015 13:44:33

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Steps 45 – 67 Nose Section Exterior Detail


With the aluminium sheet and the covering templates supplied, you will now cover the cockpit using the procedure that you have used for the rest of the aircraft.


Start by preparing pieces 1R and 1L. Cut them out and add rivet patterns with the toothed wheel, using the photo, below, as a guide.


Bend the pieces to fit the curvature of the nose, and glue the first piece 1L in the position shown, followed by piece 1R as shown in step 47. Pre-fit each piece to the one next to it, then make any final adjustments to the shape.


Prepare piece 10L. Carefully bend it to follow the curve of the aircraft’s nose.


Apply lines of rivets with the toothed wheel and shape the piece to the correct curvature, then glue it in position.


Repeat the procedure on the other side of the nose with piece 10R.


Now clad the cockpit roof, preparing and fixing pieces 8L, 9L, 9R and 8R in the positions indicated in step 51. Continue covering the left side of the nose, starting by fitting piece 2L.


Continue on the left side, gluing pieces 3L and 4L in place, then 11L. Always remember to bend each individual piece into the correct shape so that it matches the one next to it, and follows the curvature of the structure.


For the right side of the cockpit, repeat the procedure used for the left side by fitting, in turn, pieces 2R, 3R and 4R, and then 11R.



Now cover the underside of the cockpit. The centre line of pieces 5, 6 and 7, left and right, correspond to the red dotted line shown in step 55. Adjust the pieces if necessary, making sure they are even and symmetrical.

Start by preparing, shaping and gluing pieces 5, left and right, in place


Continue with piece 6, left and right.

Complete the cladding of the underside of the nose with pieces 7, left and right.


For both the upper and lower parts, remove the excess cladding material with a craft knife, and smooth it with a file (see step 59).


Take the aircraft’s nose cone S86 (from Pack 1). Apply primer to the piece, then paint it with gloss black paint.


Let the gloss black paint base dry, then apply two light coats of Alclad II Chrome with an airbrush. The shine which you want to achieve is the same as that of the sheets of aluminium used for cladding the structure.


Carefully fit and glue the nose cone onto the nose of the cockpit. Once it is fitted, try to avoid touching the pieces painted with Alclad.


Mask the cockpit as shown in the photograph, leaving the section shown exposed.


Apply a light coat of primer and leave it to dry. Then paint it black, preferably with an airbrush.


Finally, carefully remove the masking material.


From the photo-etched sheet supplied with Pack 1, remove the two windscreen wipers (pieces S44).


With a drop of adhesive, stick the windscreen wipers in the positions shown.


Now that we have covered the cockpit and crew compartment of the aircraft, put the two pieces together without glue, to check that the magnets hold the two assemblies together.

Save any unused parts in a bag labeled with the stage number for future use


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