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Douglas DC-3 official build Pack 2 Options
delboy271155
#1 Posted : 26 July 2015 02:26:56

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DC-3 Pack 2

Steps 1 – 24: Crew Compartment.

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.

Start by assembling the left side of the cabin crew’s compartment. Placing piece 2GL upright as shown, fit and glue one piece 2J horizontal to it. Use a set square to ensure that the angles are exactly 90°.

Fit and glue one of the two pieces 2H onto the assembly constructed in the previous step, again making sure that they are exactly square.

Fit and glue piece 2FL into the corresponding slots in pieces 2H and 2J.

Repeat the operations of the previous steps for pieces 2EL, 2DL and 2CL. Remove them individually from the pre-cut sheet, smooth the edges with fine sandpaper, then fit and glue them in place.

Fit and glue piece 2AL into the corresponding slots in pieces 2H and 2J.

Take the assembly completed in the previous steps, as shown in the left photograph, and fit and glue one of the two pieces 2I, after checking that all the slots in which the stringers will be fitted are exactly aligned.

Turn the resulting assembly round, then fit and glue the first piece 2K in the position indicated.

After checking that piece 2BL2 is the right way up, fit and glue it to the assembly, making sure that the slots for the stringers are exactly aligned with each other.

On the lower part of the assembly created in the previous step, fit and glue piece 2BL.

Fit and glue piece 20 in position as well.

On the inside of the assembly, fit and glue piece 2CL2 to piece 2CL.

Now move on to assembling the right side of the compartment. Fit and glue pieces 2H and 2J into piece 2GR, making sure that the result is perfectly square. Then fit and fix piece 2FR in position.

Fit and glue pieces 2ER and 2DR successively in the assembly created in the previous step.

Repeat the operations of the previous step with piece 2CR.

Fit and glue pieces 2CR2 and 2M in position as well.


As shown in the photograph, now fit and glue piece 2L in position.

Fit and glue in the positions indicated piece 2BR first and then piece 2AR.

With the assembly from the previous step placed upright, fit the second piece 2I, and then glue it in place.

Turn from Step 19 the other way round, then fit and glue the second piece 2K.

Take the stringers and test-fit them in their slots, ensuring that they make a good contact with the wood. If needed, smooth the notches with a file, then glue the stringers in place. Leave clear the area indicated for the crew compartment door.

Fit and glue the magnets in the sockets indicated by the red arrows, so that they are exactly facing those fitted in the rear part of the cockpit (assembled in Pack 1), and that they attract each other.

Cut four pieces 3mm long from the 2mm-diameter dowel. Fit and glue them in the positions indicated by the red arrows: they will act as a guide when connecting the crew compartment to the rest of the fuselage.

Apply sanding sealer or primer to the surfaces and leave to dry. Then lightly sand before painting both halves of 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 : 26 July 2015 02:34:25

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Steps 25 – 38: Crew Compartment Interior

Take the right half of the module and use a brush to paint the inside panels black as shown in Step 25.

From the A4 aluminium sheet , cut a rectangle 51 x 22mm, then, using very fine abrasive paper, lightly sand all four corners. Then glue the panel into the position shown.

From the printed sheet, cut out the signs for the inside door, then glue them on the panel in the positions shown.

From the same printed sheet, cut out the decorative elements shown. Then take the instrument panels, pieces SC. Remove any burrs then prime and paint them white.

Carefully glue the instrument panels onto the panel elements (see Step 29), being sure to centre the dials in the holes. When the glue is completely dry, use a craft knife to remove the edges of the card.

Take four handles (pieces SA), six buttons (pieces SD) and the two small plates (pieces SE) and fix them onto a strip of scrap wood with double-sided tape. Use a brush to paint them the colours shown in Step 32..

Complete the instrument panels by gluing the elements prepared in the positions shown in Step 33. Then, use a brush to apply clear gloss varnish to the holes of the dials, to imitate glass bezels.

Glue the panels from Step 33 in the positions shown.

Prepare piece 2N, which will form the floor of the crew’s compartment. Smooth it with fine sandpaper and apply wood filler if necessary. Finally, paint it maroon (same shade as the flocking) and leave to dry thoroughly.

Spread a thin even layer of PVA glue over the piece prepared in Step 35 and with a fine sieve sprinkle the upper side with red flocking powder. Before doing this, place the piece on a sheet of card to make it easy to recover the excess flocking powder.

When the glue has fully dried, remove the excess flocking powder with a damp brush. If necessary, repeat the operation of Step 36 with a further quantity of flocking powder. Store the left over powder for use later on other floor panels.

Fit the piece of flooring in the position shown. Glue it in place with a few drops of adhesive on the underside. If you wish, you can give it a slightly worn look by varying the colour of the carpeting with an airbrush.

Save any unused parts in a bag labeled with the stage number for future use
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delboy271155
#3 Posted : 26 July 2015 02:41:49

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Steps 39 – 72: Crew Compartment Detail and Crew Seats.

Take pieces SF, SG, SH, SI and C62, and the printed piece shown, which will be used to make the electronic equipment and instrumentation.

Use fine sandpaper to gently smooth both sides of the pieces shown. Then, with a rule and craft knife, lightly score along the dashed lines. These will serve as a guide when making the folds to create a box-like shape.

Apply primer to the surfaces and, when they are dry, paint both sides aluminium.

From the sheet of printed paper, cut out and glue the panel details shown onto the backs of pieces SF and SG, being careful to position them correctly. Let the glue dry and then apply a coat of gloss varnish to the dials to imitate the glass.

With flat-nose pliers, bend the sides of the two pieces prepared in Step 42 so as to make two small boxes. Glue the sides to each other with glue applied to the inside, so that the boxes are rigid. To complete the two instrument boxes, take the elements shown (four handles SA and eight buttons SD) and, having attached them to double-sided adhesive tape, paint them black and red, as shown in the photograph. Glue the pieces prepared in Step 44 in the positions shown. Also, glue the cable connectors (SI) and the handle (SH) onto the instrument box on the right, after painting them black.

Cut two pieces of red wire, each 20mm long. Glue one end of each of the pieces to the cable connectors at the front and, after bending them carefully, fix the other ends to the back of the instrument box, as shown in Step 46.

Paint the larger fire extinguisher (C62) as shown in Step 47. Prepare and fit the mounting bands as you did in Pack 1 (Step 50). Prepare and finish the second fire extinguisher (C61) in the same way.


From the sheet of printed paper, cut out the shape shown in Step 48, which represents the lining of the inside walls of the crew compartment. Fix it to the interior with PVA glue (see Step 49).

Fit the smaller of the two navigation instrument boxes, completed in Step 45, in the position shown in Step 49, and glue it in place. Then, fix both the extinguisher’s in the correct positions.

Next, glue the larger instrument box, completed in Step 46, opposite the extinguishers, in the position shown in Step 50.

Take pieces VA, SD10, SD11, SD12, S92, S90, S18 and S19, which will be used to make the twin seats for the co-pilots. Use a fine file to remove the square fitting on the underside of part S92.

Make the two seat backs with pieces SD12. Glue them together and then use a fine file to remove any burrs.

If necessary, slightly thin the plastic rod VA with fine sandpaper so that it will slide more easily. Check that the plastic rod can pass easily through the holes in the seat backs.

Separate pieces S05 and S06 from the photo-etched sheet and glue them onto pieces S18 and S19.

Cut pieces S09 and S10 from the sheet of photo-etched seat parts and use flat-nose pliers to bend them as shown in Step 56.

Cut two pieces of plastic rod VA to the length shown in Step 57, and slide them through the holes in the pieces from Steps 55 and 56, to align the seats correctly.

Glue the contact areas (indicated by the arrows) together, and once the glue has set, remove the plastic rods.

Take pieces S03, S04, S07 and S08 from the photo-etched plate. Bend the ends of parts S07 and S08 over as shown in Step 59.

Apply primer to all the pieces which will make up the co-pilots’ seats, as shown in Step 60. Then paint the inside of the seat structure and pieces S07 and S08 aluminium, and paint the internal faces of the piece made in the previous step, brown.

Paint the plastic rod VA aluminium and the seats SD11 and seat backs SD12 Mediterranean blue. Paint the individual pieces with primer before applying the colour.

Fit the seat backs SD12 in place by passing the plastic rod VA through the holes in the seat backs and the structure. Then cut the rod flush on both sides. Also pass the rod VA through the holes in the front part of the piece and cut it flush on both sides.

Glue pieces S03 and S04 to the outer sides of the seats. Complete the piece by painting the side supports of the twin seats brown.

Fix pieces S07 and S08 to each side of the piece, after painting them with primer and then aluminium paint. Leave unpainted the parts which will slot into the floor of the module (indicated by the dashed ovals).

Glue in place the seat cushions SD11, painted in Step 63.

Paint the armrests S90 and S92 French blue, and with a brush add the aluminium details on the fronts of the side armrests S90 (indicated by the dashed circles). Then glue them in place. Paint the headrests SD10 off- white, then glue them onto the seat backs.

Fit and glue the twin seats in the position shown in Step 72. If the slots for fixing the seats to the floor are partly obstructed by the flocking, clean them up by carefully running the craft knife blade around the slots.

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



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delboy271155
#4 Posted : 26 July 2015 02:52:08

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Steps 73 – 101: Compartment Door and Airframe Skin

Take pieces C14, C15 and C16, comprising the frame, the hinges and the door into the crew’s compartment. Check the positioning and free movement of the hinges on the frame and, if necessary, adjust them gently with a fine file.

After applying primer, paint the pieces green. When the green paint is dry, use a brush to paint the inside edge of the door frame black.

Take the left part of the compartment, then cut the interior lining shown from the printed sheet and glue it in place.

Fit and glue the access door frame (prepared in Step 75) in the left half of the compartment.

Use fine sandpaper to roughen the contact areas between the two halves of the compartment so they will adhere properly.

Fit the two halves of the compartment module together. Check that the upper and the lower parts are making contact at both the front and the rear, then glue the pieces together. Gently hold/clamp them together while the glue sets.

Carefully fill any gaps in the join between the two halves, then retouch the paint where necessary.

You now begin the aluminium fuselage. Spend a little extra time on these steps to achieve good results, each piece must be carefully prepared before you form it to the shape required and it is glued in place.

Take the self-adhesive sheet (Mod 2 Covering Template) and stick it to the aluminium sheet, smoothing it down carefully to avoid any air pockets.. Keep the remaining part of the sheet; it may be useful if you need to remake any of the pieces.

Use a sharp craft knife to cut out piece A2a, cutting out the external outline and the shape of the door opening inside. This will be the first piece to be fixed, around the door, and it is in relation to this one that the other pieces will be positioned.
Always bear in mind that the side of the aluminium sheet on which you have glued the adhesive sheet is the inside one. For the model to have a perfect finish, be sure to protect the outer side from scratches and dents.

Carefully smooth the edges of the aluminium piece with fine sandpaper or a fine file, then remove the sheet of adhesive paper.

Lightly Sand the internal surface of the sheet so that the paint you will apply later on will adhere better. Then fit the piece, making sure the door opening is aligned. If necessary, touch up the internal outline of the door with a craft knife or a file.

Using cylindrical objects of various diameters, progressively round the covering piece to give it the necessary curve for the position it will have on the aircraft.

In forming the curve which the aluminium piece must have to fit the fuselage, do it in such a way that the shape is smooth and continuous. Do not apply any adhesive yet.

With a fine-point marker pen, mark on the outer perimeter of the piece the places where the ribs and stringers intersect.
Transfer the markings made in the previous step onto the inside of the piece and join them to indicate the position of the ribs and stringers. Use the ruler for the horizontal lines and draw the central lines following the curve of the edges.

Use the rivet marking tool and metal rule to go over the lines drawn in the previous step to make the marks representing the rivets. In the photograph on the right, you can see how these lines show up very clearly on the outside of the piece.

Use alcohol or acetone to clean off any traces of the marker pen, then apply metal primer and, once it is dry, paint just the interior side of the piece green and leave it to dry.

With a paintbrush, apply contact adhesive along the lines of the rivets on the inside of the aluminium piece and then to the ribs and stringers of the compartment. The points where glue is applied are indicated by the dashed lines in the instructions.

Once the contact adhesive has been applied, wait until it is touch-dry before positioning the aluminium. The door opening defines the position that the covering piece will have in relation to the framework. (Use of “Evo-Stik Timebond” contact adhesive, allows for fine adjustment and can be purchased in tube form).

Once the door opening is perfectly aligned, check that the rest of the piece fits smoothly to the curvature of the fuselage.

Repeat the operations of Steps 89 to 95 with pieces A2b and A2c, checking each piece in position without glue before giving it its final shape. Check that each piece fits the structure perfectly and that the lines of rivets are continuous.

Finish covering the left half of the compartment, checking that the joint lines between the elements do not have an irregular finish.

With a sharp craft knife, adjust and even up the edges of the assembled elements by making a clean and tidy cut along the red dashed line indicated in Step 98. Also remove the excess aluminium of pieces A2a and A2c from the front and back of the compartment. Smooth the edges and finish with fine sandpaper.

As we did previously, prepare the aluminium sheet and clad the right side of the compartment. To achieve a good result, check that the elements fit together, and also that they neatly butt to those pieces fitted around it.

The panel joint lines won’t be flawless; at the end of the assembly process, the instructions will explain how to improve the appearance later on in the build.


Remember to carefully store any unused or left over parts in a labelled bag.


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