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Douglas DC-3 official build Pack 3 Options
delboy271155
#1 Posted : 25 August 2015 19:11:15

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DC3 Pack 3

Steps 1 – 18 Passenger Cabin Left Side

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 left 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.

Start by assembling the left side of the cabin. Fit and glue piece 3F to pieces 3A and 3B as shown, checking with a set square that the angles are exactly 90°. Note: Part 3B must have a single hole at the end where it is joined to Part 3F, as indicated by the red arrow.

Fit and glue piece 3G onto the assembly constructed in the previous step (see photograph).

Continue in the same way, fitting and gluing pieces 3I, 3J, 3L, 3M and 3O in turn.

Turn the whole assembly round and position it as shown in the instructions. Fit and glue pieces 3C, 3D and 3E in their positions.
Also fit and glue pieces 3H, 3K and 3N. You will now have finished the first part of the structure.

Now move on to assembling the second part of the passenger cabin. Fit and glue pieces 4A and 4B into piece 4F, as shown. Remember to check with a set square that the interior angles are 90°. Note: Part 4B must have a single hole at the end where it is joined to Part 4F, as indicated by the red arrow.

Fit and glue piece 4G into the relevant notches in pieces 4A and 4B.

In the same way, fit and glue pieces 4I, 4J, 4L, 4M, 4O, 4P and 4R.

Turn the assembly round and position it as shown in the instructions, then insert and glue pieces 4C, 4D and 4E in turn. Let the glue dry and then add pieces 4H, 4K, 4N and 4Q. You have now completed the second part of the left side of the cabin.

From the bamboo dowel supplied with pack 2, cut four pegs, each 3mm long. Fit and then glue them into the holes in the front side and rear side of the cabin framework you have just completed as indicated in step 11.

Using the two dowel pegs inserted in Step 11 as a location guide, glue the two pieces together. Use clamps to hold the framework together until the glue has set.

When the glue has set, fit and glue piece A1 in place.

Fit and glue piece A2 in the same way.

Position and glue the stringers in the notches along the framework (see photograph). Touch up the notches with a small file if necessary: the stringers must be flush with the profile of the fuselage.

Also fit and glue the stringers to the lower part of the assembly as shown in step 16, but do not fit them in the roughly square areas indicated by the red dotted lines in the instructions.

Also glue stringers to the inside of the assembly as shown in step 17; they will be used to support the interior lining of the cabin.

Apply wood filler and leave it to cure. Then paint the assembly green.

Save any unused parts in a bag labeled with the stage number for future use
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delboy271155
#2 Posted : 25 August 2015 19:30:44

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Steps 19 – 36 Passenger Baggage Rack


Take the baggage rack for the left side of the cabin, piece CBAGG1. Remove any imperfections with a fine file and abrasive paper, then apply primer and leave it to dry. Then paint the baggage rack beige and leave it to dry.

With a brush, paint the underside edge of the baggage rack Mediterranean Blue. This is the same colour as that used for the seat backs assembled in Pack 2.

Paint one side of one stringer Mediterranean Blue and leave it to dry. Glue it to the lower part of the baggage rack as shown and cut off any excess at each end.

Finish the lower side of the baggage rack by painting the seven spots (parts SD) black and gluing them into the positions shown.

Fit the baggage rack to the assembly from Step 18, making sure that it is flush with the upper side, then fix it in position with cyanoacrylate glue applied from the rear side.

Prepare a window frame by assembling two pieces F1 and two pieces F2. To assemble it correctly, make sure that the part codes on the two pieces F1 are both facing in the same direction, because the pieces are not symmetrical (check step 25).

Lightly sand the frame, then fill and sand the characters ‘F1’ on the inside. Apply wood filler if necessary and paint the whole Mediterranean Blue. Leave it to dry.

Take the ‘Interior lining template’ sheet of self-adhesive paper and the ‘Plastic sheet’ and stick the sheet of paper to the plastic (see step 27).

Using a sharp craft knife, cut the sheet of plastic following the printed outlines, so you end up with the two pieces shown in the photograph. Carefully peel off the adhesive paper.

Apply primer to both pieces G1 and G2, and leave them to dry. Refer to step 29 for the side to colour piece G2 and, when it is dry, paint it the same colour (beige) as used for the baggage rack.

Using a pencil, draw a faint line two millimetres from the lower edge of piece G2 in the position shown in the instructions. Then paint the area below the line drawn on piece G2 in Step 30 Mediterranean Blue, as well as the area below the windows. Also paint the whole of piece G1 and leave it to dry.

WITHOUT BEING GLUED, fit the frame prepared in Step 26 in the position indicated on the fuselage. Arrange it so that the outer edge is flush with rib 4I.

Use the position of the frame inserted in the previous step as the reference point for fitting piece G2. Fix it with cyanoacrylate glue to the two ribs adjacent to the frame, but be careful not to glue the frame.

Press piece G2 against the ribs to follow the curve of the structure, then fix it in place by applying adhesive to the area indicated within the red circles in step 34, working from the centre towards the ends.
Piece G2 must remain in contact with the curvature of the ribs and also line up with the lower profile of the baggage rack CBAGG1.

Remove the window frame that you used as a reference point.


Save any unused parts in a bag labeled with the stage number for future use
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delboy271155
#3 Posted : 25 August 2015 19:36:45

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Steps 37 – 49 Interior Detail

In the same way as Steps 33 and 34, fit and glue piece G1 below piece G2.

Paint a stringer Mediterranean Blue and glue it into the area of the join between the baggage rack and piece G2 as shown. Remove any irregularities there may be on both sides of the stringer.

Paint one side of the two stringers with aluminium colour. Glue one above and one below the windows, as shown. Cut off any excess at each end.

Turn the assembly over and position it as shown. From the back, use Mediterranean Blue to paint round all the window openings of piece G2 as shown.

Turn the assembly over and position it as shown. From the back, use Mediterranean Blue to paint round all the window openings of piece G2 as shown.

Glue a piece of acetate to the convex side of the seven frames (using PVA glue, because cyanoacrylate would affect the acetate). Remove the excess acetate with a sharp craft knife.

Fit the seven window frames, centring them exactly on the openings in piece G2, if necessary, touch them up with fine abrasive paper. The acetates must be flush with the ribs (see inset). Fix the frames carefully with cyano glue.

Take the ‘Paper for curtains’ and cut out seven pieces, 24mm long by 12mm high.

Using a ruler, make a series of parallel marks spaced 1.5mm from each other, pressing the paper with the blade of the craft knife to make an impression without cutting it as shown in step 45.

Using the lines impressed with the craft knife in the previous step, fold the paper to give it concertina folds, as shown.

Apply a very small amount of PVA glue to each of the folds and pinch them together them with a clothes peg or small clamp. In this way, when the glue has dried you will have made a curtain ready to be put in position. Repeat the operation to prepare the remaining six curtains.

With two dots of adhesive on the aluminium-coloured stringers which you fitted above and below the windows (see Step 39), glue the seven curtains onto one side of each window as shown. Check the position with the inset photo of step 49.

Save any unused parts in a bag labeled with the stage number for future use
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delboy271155
#4 Posted : 25 August 2015 19:48:17

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Steps 50 – 76 Outer Covering

Take the die-cast elements BA1G, C2G, C1G and C3G shown in the detail and carefully remove any imperfections from them. Be careful not to damage the rivets! The pieces will be painted later, so look after them carefully in the meantime.

Clean piece BA1G with alcohol or acetone and fit it into the position shown. Do not glue it yet.

Take a spare strip of aluminium and use it to check that the die-cast piece BA1G fits in place (see step52), and will lie flush with the surrounding structure when it is clad. Then, apply adhesive to piece BA1G and stick it in place.

Clean piece C1G and fit it carefully to the underneath of the assembly. Do not glue it.

As in Step 52, use a piece of aluminium to check that piece C1G will lie flush with the rear covering, before fixing it to the inside of the structure with glue.

Following the same procedure as before (Steps 51 to 54), fit and glue piece C2G in position. Finally, fit and glue piece C3G next to the previous one.

Take the die-cut aluminium piece for covering the windows A3L1 and rub one side of it lightly with fine abrasive paper (see step 57 for which side to sand).

Put the piece in position with the non-sanded side facing outwards, and make marks in line with the vertical ribs. The process of positioning the aluminium is exactly the same as that used in Pack 2 for covering the left side.

Transfer the marks made in the previous step onto the inside of the piece.

With a ruler and a toothed wheel, trace the vertical lines of the rivets, joining the marks made in Step 59. Make four horizontal lines of rivets: two of them 0.5mm from the upper and lower edges of the piece and two at the same distance above and below the windows.

After cleaning off the marks made by the marker pen from the piece, with alcohol or acetone, position it on the fuselage and fix it with contact glue, centring the windows exactly.

Prepare a piece of aluminium covering A3L2, following the procedure described in detail in Pack 2 (Steps 81 and following). Form the piece to match the shape of the fuselage which it will cover, then fix it so that it adjoins piece A3L1.

With a marker pen, mark the ribs and stringers on the outside of the piece. Extend these marks onto the inside and join them with lines, which will show where the rivets will be.

Run the toothed wheel along the lines you have drawn, then clean all the marks off the piece.

Curve the piece so that it fits the fuselage exactly, then fix it in position with contact adhesive.

Repeat the operations carried out previously to fit and glue in turn pieces A3L3, A3L4, A3L5, A3L6, A3L7 and A3L8.
Note: It is very important to test-fit each piece on the fuselage before adjusting it and gluing it in place.

Prepare piece A3L10 as previously. Remember to sand the inside lightly.

Piece A3L10 must be shaped to fit the fuselage in the position indicated in the photograph. Take your time and work carefully on these pieces, which demand patience because of their complex shapes.

Use a cylindrical object to give the piece its initial form, then use your fingers to form it to the required curvature.

Once the piece A3L10 is the right shape, place it in the position it will occupy on the fuselage, in such a way that it adjoins both pieces A3L1 and BA1G. Do not glue it yet.

Continue working on the piece by marking the lines of the rivets, which must line up with those on the pieces already fixed in place on the fuselage. Finally, give the piece its final form and glue it to the structure.

Repeat the same procedure with pieces A3L11 and A3L12. Always test-fit the piece on the fuselage first, checking that it fits the adjacent ones properly before gluing it.

Continue covering the fuselage, preparing and fitting pieces A3L9, A3L16, A3L13, A3L14 and A3L15 in turn.

To achieve a good result, the covering of the aircraft must be as neat as possible. Do not worry about the areas not yet covered (circled in step 74) because they will be completed later.

Detail of the covering round the windows can be seen in step 75.

This shows the appearance of the completed left side of the passenger cabin after the assembly steps of this pack. Do not worry about visual differences in the finish of the various die-cast elements and the aluminium covering: the necessary instructions to make them uniform will appear in future instructions.

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