LATEST NEWS

Sept07- March 08.

No sooner than the last update was penned, almost 4 months have passed! There is much to report since September. Over the past 4 months we have been very busy with rebuilding the cockpit floor, finishing n01 engine bay, preparing the ferry ventral tank for fitting, as well as progressing the refurbishment of the re-heat pipes, and many other small jobs that continually occupy ZF579's crew. Not to mention general care and maintenance for her. Below we have listed the jobs that have been completed or ongoing since last September.

-The leading edge checks below, were completed ahead of time with no problems found, the panels have now been refitted and the repairs to the wing tank venting system were completed by way of replacement new valves.

-The cockpit floor and associated flying controls bearings have been renewed and finished and re-laid, along with a new brake control cable. The ejection seat has also now been re-fitted after a check over and few minor issues sorted, completing the cockpit, ready for the open season.

- Our attention then turned to mothballing no1 engine bay until installation of the engine in the summer. This required the ventral tank to be overhauled, since the  skins were in  pretty poor condition due to corrosion. The corrosion was removed and the skins re-flatted to a high luster once again. We then fitted the tank to seal the engine bay. The tank now looks and operates as good as new.

-No2 engine bay is not quite finished yet, still requiring a month or so in work. The top hatch will be opened in the next few weeks in order to finish this bay off  ready for engine install in the summer.

- Attention will continue to  focus on treatment an inhibition of the re-heat bays, since they are very dirty and dry. The work encompasses degreasing, cleaning, eliminating minor surface corrosion, then re- painting with 650 degree high temp paint for protection against the heat. Once complete, we will refit the new air turbine gearbox, and numbers 1 and 2 jet pipes. Mechanically 671 is almost done. cosmetics wise, she's not too far off either. We will repaint leading edges, wing tops and elevators soon to complete the cosmetics.

Last but not least.  for the last year we have enjoyed the help and presence from our latest Lightning volunteers. Our young friends TOM and Kirsty. Tom is our fresh faced Lightning apprentice, who is learning skills and knowledge on the Lightning and enjoying every minute of it. Tom comes down to GAM every Saturday, along with another of our young volunteers Kirsty whom is also learning many new skills on the GAM collection every Staurday.

  New cockpit elevator cross link bearing ready to be fitted under the floor. This eliminated our 'slop' issue.

The same cross link bearing alongside new, just before new bearing races were fitted.

No1 reheat air motor control trunions and bearings being renewed.

No1 reheat area in the process of being cleaned and re-painted with high temperature paint

Reheat pipe area after clean up, and application of new high temp protection

579 restored ventral tank being fitted, before final polishing, and decals.

tank fitted and decals/markings being re-applied.

Cockpit floors re-laid after brake cable replacement, and new tail plane bearings.

port side cockpit and throttle box during throttle rigging process.

A night shot of 579's cockpit lit up during cockpit Lighting checks.

579's reheat pipes

OVERVIEW OF WINTER WORK 2007

• Cockpit floor elevator cross link refurbished

• Cockpit brake control cable replaced with new item

• Cockpit floor panels replaced

• New cockpit control stick boot fitted

• Cockpit throttle box and teleflex rods rigged for engine fitting

• Cockpit canopy locking tubes freed and serviced

• U/S Ejection seat motor replaced with serviceable item

• Ejection seat negative g strap replaced

• No1 interspace area cleaned, any surface corrosion eradicated

• Reheat bays cleaned and high temp pant applied, in readiness for Air turbine fit

• ventral tank refurbished and fitted

• New canopy air drier ac motor finished.

• nO2 engine hatch freed in preparation for removal and engine fit

• broken port fuel cross feed actuator removed and replaced with serviceable item

• port wheel bay locks sent away for repair and rebuild

• port wheel bay and retraction bay re-build progressed

• no1 bay engine turbine exhaust ducts freed and lubricated

• No1 and no2 reheat air motor control trunion bearing assemblies refurbished.

• Ejection seat refurbished and refitted to aircraft

• Avon 302 3monthly engine inspection, and inhibition carried out.

• Reheat pipes relocated to rebuild area.

April 07 - Sept07

After a pretty unsatisfactory summer weather wise, much of the aesthetic work we had hoped to achieved, wasn't done, so we diverted our attentions to other areas, normally saved for the winter months. The final and minor engine bay leak below has been rectified and tank pressure tests are complete and remarkably leak free for such an old an usually problematic design, in fact for a Lightning 53-671 is out of character, being a leak free one, even under 10 psi of positive tank pressure.  

We have begun to remove the outer most leading edges for a clean up and final inspection of the sub systems inside ( see pictures below). We have also revealed an old long standing problem with the cockpit flying controls on this airframe. Since we have had her, she has had a strange obstruction and slop problem in the elevator gearing in the cockpit. Upon disassembly of the cockpit floor, we removed the control pivot to find the bearings race missing a large number of its balls. All the balls were loose in the compartment below. ( see pictures). We have now ordered a new set of races and bearings to rectify this problem.

port leading edge removed, revealing the flying controls and hydraulic systems for a clean and inspection.

cockpit elevator cross link before removal to  eliminate  a mystery obstruction and slop

cockpit elevator cross link removed and bearing assembly removed to replace faulty race found.

ZF579 uncovered a few weeks ago in the sunshine

December 06-April 07

Well, mainly workshop activity and electrical system anti det exercises to report over the winter. No1 engine bay is just about complete, leaving n2 reheat teleflex cable to be installed. A final bay pressure test, revealed a minor leak, to be sorted out in the next couple of weeks. ZF579 is looking pretty grotty and dirty after the winter, with her winter coat of waxoil, but not for long. A wash is in order over the next few weeks.

OVERVIEW OF WINTER WORK 2006

• Cockpit under floor structures inspected and passed with a clean bill of health. Floors to go back down soon.

• Cockpit internal canopy control handle removed and refurbished. U/s canopy inflation valve identified. 

• Canopy interspace115V 3 phase, demister blower, sent off for refurbishment.

• Port wheel bay door locks sent to Prestwick  for refurbishment, to return soon.

•  NO1 and n02 throttles rigged

• n02 Engine hatch prepared for removal.

• Ferry ventral tank worked up, ready for fitting.

• Ventral tank AC pump pressure gauge replaced.

• Flight re-fuelling coupling fuel leak rectified.

• Cockpit brake control cable removed. U/S. replacements to be procured.

• Avionic flight instrumentation simulation rig build started.

• Cockpit temperature control wiring bundles completed.

• New port leg retraction components procured.

• Cockpit Ram air valve now working.

• Reheat pipe refurbishment bay set up, for pipes to be relocated in the next week, where refurbs will begin.

• Ventral tank internal inspection completed, and passed with a clean bill of health.

• 2000 Lightning nuts, screws and bolts, sent away for refurb and new Zinc passification.

• Broken hot air water separator relief valve replaced for serviceable item.

• Fuel gauging system "zeroed" and adjusted. Fuel indication system signed off and finished. Water drain tool acquired.

• Broken IFF channel selector box,  repaired, ready for fitting.

• UHF/VHF relay box refurbished. PTR175 radio tested ok. Intercoms working ok.

• New old  saudi stock fuel tank Invward vent valves procured, to be fitted if spares are required.

September/December 06

With no1 engine bay fairly well complete. Focus shifted to preparing the air frame for winter. A full clean down and wax oil ensued in November. Attention then shifted to removing the canopy and ejection seat, to enable the cockpit floor removal. Removal of the floor, will enable the brake control cable to be replaced, completing the aircraft braking system refurbishment. Work has now started on the port undercarriage bay restoration too. Another 1000lbs of fuel will be introduced once new fuel tank inward vent valves have been installed in February. Work has also started on No2 engine bay and both re-heat pipes.

Canopy removed, to remove ejection seat and cockpit floor

Ejection seat removed to workshop for inspection.

579 lights up a peas souper!

July/September

The last two months have been spent wrapping up no1 engine bay after previous fuel pressure tests. The bay is just about ready for engine installation now, with just a couple of outstanding components unserviceable, which are currently in the process of being manufactured. As such the bay will be 99% finished within the next few weeks. At this point the ferry ventral tank will be fitted to mothball the bay until engine installation summer 2007. The ferry ventral tank is currently in the process of being refurbished, before fitting. Work has also been underway to complete the pitot /static instrumentation pipe work, which is now complete. Work will commence shortly on wrapping up no1 inter space bay, and no2 engine bay.

No1 engine bay

579 parked opposite the workshops

David meets Goliath!

May/June

Main landing gear retraction tests, and door fairing rigging. Aileron surfaces prepared for function tests, nose gear up lock walking joint leak rectified.

airframe polished, and gear doors prepared for installation.

April/May 2006

In the last few days we have introduced another 2000Lbs of AVTUR. fuel currently stands at 3700lbs. No more fuel will be introduced now, until we are ready to pressure refuel, shortly after engine installs, planned for summer 2007.  A warm welcome extended to Phil Kingsbury, a fellow AALO team member and stalwart Lightning nut case, just like the rest of us!  Phil joins the Project53 team, and will be a valuable hands on crew member. Welcome aboard Phil!

All current air frame, propulsion, and fuel system components stock matched with in service component cards, and hours logged. Youngest items to be fitted and in service component  card logs resumed.

  Topping up the tanks with go juice!

April 2006

The start of this month has seen the last  major wall tumble, which will allow us to change up a gear and surge ahead (no pun intented!) and finish no1 and n02 engine bays within the next 6-8weeks, allowing us to move to the final phase of the project. Wiring and re-heat pipe refurbishment. 

Fuel tank integrity problems and pressurisation tests held us up for almost 18 months. We now have a leak free Lightning, a rarety amongst Lightnings. We count ourselves lucky that the Saudi Lightnings had a pampered life in service, and a mid life tank re-seal. This, along with having all of ZF579's in service maintenance records, has helped us to identify and rectify leak problems, some of which she undoubtedly flew with.

 Main planes pressurised and leak tested, starboard leading edge fuel tank plate seal leak identified and rectified. defective outward vent valve identified.

Centre section tank integrity established.

Wing to wing transfer tested ok

Ventral tank coupling and ground re-fuelling galleries integrity established.

pressure testing tool                     happy chaps, pressure testing

Jan-March 2006

Complete fuel contents system strip down and refurbishment. Tank senders, reference units, amplifiers, coax , and gauges removed

cleaned and bench tested, ready for re - installation to air frame.

new water drain blanks manufactured and fitted

Further work carried out to NO1 Bay subsystems. Throttle runs inspected and re-greased

New Ventral tank fuel coupling installed

New undercarriage lower radius rod pivot pins ready for fitting.

December 2005

Air Turbine gearbox refurbishment completed. To be fitted to air frame in due course

November 2005

Ejection Seat and canopy made safe for removal

Sept-October 2005

Fuel draulic and Re-heat fuel systems pressure tested

1200LBS AVTUR introduced to main tanks.

August 2005

Fuel gauge wiring  fuselage looms identified and re-connected.

Controls flying surface gear inspected, greased, lubricated, ready for priming and testing of flying surfaces.

No1 engine bay final heat shielding installed.

Port air brake synchro bracket repaired.

June-July 2005

Rear and centre Ventral tanks refurbished and re-fitted, ready for fuel testing.

Main wheels have been re-furbished and brake units serviced, refitted. New nose wheel and tyre fitted.

Air turbine gearbox re-furbishment complete, fitment and testing to take place.

Fuel amps tested and calibrated with smiths fuel test set. Ready for re-installation

March-April 2005

Well, a successful past couple of months for Project 53 and ZF579. Now over the top of a steep climb, progress is coming swiftly.

After almost 20 years laying in bits, 579's hydraulic systems were finally completed and fully tested this month. After a suitable source of OM15 and Nitrogen was found, we primed , bled and tested the services hydraulic pluming with a ground servicing rig. 2 minor leaks were rectified within 24 hours and the system is now fully operational. This makes exercising the various systems a synch now, flaps, canopy air brakes, wheel brakes and artificial feel systems are now exercised for an hour a week, there is no better way to preserve the systems than using them! A well done to all!

579's wheel brake system has also received attention. The main wheel brakes have been cleaned up ready for fitment, and the brake control unit has been tested ok. The canopy and ejection seat will be removed shortly, so that the break control cable can be replaced, completing the braking system.

The lightning spares stores has grown too!, with procurement of a few more spare parts, including spare re-heat pumps and ignition components. Much needed spares to aid 579's future conservation. We are always interested in spares, so you know where to come if you have any to get rid of!!