BUILDING THE BACK PLYWOOD PANEL FRAME

 

PANEL #1 GOES TOGETHER WITHOUT A HITCH

 THE MATERIAL IS ¼” FIR PLYWOOD, JUST AS IT WAS DURING WWII WHEN BOEING BUILT THEM. THE FRONT, BACK AND BOTTOM HAVE 1/16” DEEP SLOTS ROUTED INTO THEM AT THE PRECISE LOCATIONS OF THE FOUR VERTICAL RIBS. FIRST THE BOTTOM AND BACK PANEL ARE GLUED AND CLAMPED TOGETHER. TIGHTBOND WOODWORKING GLUE IS USED ON ALL JOINTS. THEY REMAIN CLAMPED FOR 24 HOURS THEN THE FRONT PANEL IS ADDED. ON DAY THREE THE RIBS ARE FITTED AND EVERYTHING IS SQUARED UP AND CLAMPED AS SEEN HERE. ONLY THE SMALL LEFT END, WHICH WASN’T ADDED TILL THE NEXT DAY.

THE WHOLE ASSEMBLY WAS CLAMPED DOWN TO A SOLID WOODEN DOOR TO MAKE IT FLAT. THERE HAS BEEN TREMENDOUS ATTENTION TO THE DETAIL IN THE ORIGINAL BOEING DRAWINGS OF THESE PARTS. SLOTS AND HOLES FOR CABLES AND HOSES ARE IN THE PRECISE LOCATIONS STIPULATED IN THE DRAWINGS.

 

 

FULL ATTENTION TO DETAIL, AS THE PANEL BRACKETS ARE ADDED TO HOLD THE PHENOLIC PANELS TO THE FRAME RIB ON THE RIGHT CO-PILOT'S SIDE. ALL THAT REMAINS NOW IS TO GLUE THE TOP SHEET IN PLACE AND GIVE THE WHOLE WOOD FRAME A GOOD COAT OF FLAT BLACK PAINT. THEN THE PHENOLIC PANELS WILL BE REASSEMBLED FOR THE FINAL TIME AND ALL THE INSTRUMENTS ADDED.

 

 

FINALLY THE TOP GOES ON, FITTING TIGHTLY INTO THE 1/8" ROUTED GROOVE IN THE BACK OF THE FRONT PANEL. EVERYTHING IS GLUED AND CLAMPED FOR 24 HOURS.