LATEST NEWS
June 2010.
Until
next time… some pictures below..
Above.No1
engine on its way to the engine shop
Above.Both
302’s, in the engine shop. Await inspection
579,
looking resplendent.
Above.
Some of the hundreds of screws, returning from the plating shop
It is with deep sadness the project53 team have to report that, on the 14th Nov at approx 12:05pm, Dave Stock was tragically killed in Thunder Cities Lightning XS451, whilst displaying at Overberg airshow in South Africa. XS451 experienced handling difficulties resulting in the loss of both the airframe and Dave. Dave Stock was a highly experienced and well respected test pilot with over 15,000hours of experience, and will be sadly missed by everyone. RIP Dave Stock.
March 08 - November08
8
months have passed since the last update on Zf579 engineering progress, but the
team have been extremely busy, with much progress to report.
Work has continued at a steady pace over the last two quarters on ZF579. Our
primary goal has been to prepare number 2 engine bay to the same standard as
number one bay, ready for engine fitting. number 2 bay is just about finished,
bar a few replacement P clips. That completed, it leaves us in a position where
both engines can be fitted to the air frame. We have decided to leave the engine
installs until the very last moment, since once they are fitted, our flexibility
and access to areas of the airframe are massively reduced.
-
Our
refurbished Air Turbine Gearbox has now been fitted to the air frame, and we
have tested it for vibrations, oil leaks and hot air leaks, with an hot air
Trolley. This exercise went flawlessly, with the gearbox performing as per spec.
Now that the gearbox is fitted, we can move ahead and finish fire bottle
inspections, then one final hydraulic leak check will enable us to re-fit No1
and No2 inter space pipes over the winter. What little corrosion was found in
the inter space areas has been removed, leaving us with no worries about what is
going on inside the aircraft.
We
are well progressed with the re-heat (or afterburners in US speak) pipes now,
with the first, number1, ready to be fitted back together and tested with a
ground rig. Although the pipes looked in a very sorry state at first glance,
they have proven to be very straight forward, once the master ring gears were
removed and freed off. Minus a few broken studs which will be replaced, the
pipes have put up relatively little fight.
Another
goal reached recently was the correct re-fitting of the rudder and a full leak
down and function check of the Controls Hydraulic circuits. These were successfully
pressure tested at full spec. Whilst pressure was applied, the ailerons, tail
planes and rudder were all successfully tested.
The
wheel brakes have also now been successfully tested after an un-cooperative
walking joint (brake hydraulic pipe) was rebuilt.
A
minor fuel gauging problem, as a result of some mystery water contamination in
the port fuel tank, resulted in some problem chasing recently. This has now been
solved and the gauging re-calibrated with a test set again.
We
are now then in the last stage of the project, which is to concentrate on
finishing the wiring and installing the engines next year. We anticipate that
the wiring should be finished by March, and the air frame will then wait until
milder weather in April or May, for both engines to be installed. It's then all
systems go for first shake down runs after almost 22 years dormant. We are
determined to get to this point early next year.
After
8 years of toil, sweat, blood, sacrifice, tears and painstaking rebuild to high
standards, we are 90% there, and she will absolutely run!!. This has been no
ordinary "lets get this old jet running again" project. 579 has taken
so long because no compromises have been accepted! A very strict, paced approach
has been taken with her, since she is unique. Every single component has been
removed, tested and refurbished where required, and then tested again for good
measure, before being refitted to the airframe. Every bolt wire locked, every nut
split pinned, every pipe leak tested. Every job has been documented using RAF
form 700's, and any parts manufactured, have been manufactured and released by
qualified C and C specialists on site. As far as Lightings go, the team is about
as clued up as you can get, with all ZF579 team members also being primary
engineers on the return to flight project for XS422 T5 Lightning in USA. We have also been
able to draw on the vast knowledge pool that makes up the rest of XS422's
primary team and other groups, each specializing in different Lightning trades.
Propulsion, instrumentation, airframes, etc.
Of
particular benefit to us, has been ZF578 and XS458 airframes, particularly XS458
(a live T5) which has served as a useful test bed on several occasions. Overall
the local team now has in excess of 10,000 + hours on F53/F6 type Lightnings, so we are
confident that 579 has already presented us with our biggest challenges, which
are now behind us, we hope!
Snags
aside, we are looking forward to going from having the only "live" F53
Lightning in the world to the only fully functional running F53 Lightning in the
world in 2009!
AIR TURBINE GEARBOX FINAL ASSEMBLY
ZF579's original and refurbished Air Turbine Gearbox. Airframe being prepared
for fitting.
Same gearbox and ancillary pipe work/generators fitted,
ready for testing.
Gearbox being tested for speed checks, hot air and oil
leaks, before being signed off.
Gearbox over speed emergency shut down valve
refurbished and ready for re-assembly.
An unusual shot of a Lightning gearbox being fitted. Here
you can see the impeller that spins at 14,000 rpm. Middle of picture
HYDRAULIC FUNCTION AND LEAK
DOWN TESTS OF FLYING SURFACES
Ground servicing hydraulic rig applied for leak down
checks and flying surfaces checks.
As above
Elevators/stab being put through their full range for FOD/Obstruction tests and
leak checking.
Port surfaces being checked for free movement, and leakage
tests of powered flying control connections.
Process repeated for the starboard side.
NUMBER 2 ENGINE BAY WORK
Number 2 engine bay area being prepared for engine installation.
Same bay, showing the access hatch open.
REHEAT/AFTERBURNER PIPES
No1 Reheat pipe at the start of its refurbishment. All screw jacks and main ring
gear seized solid. Rust can be seen
Same pipe with actuating shrowd, screw jacks, rollers and
main ring gear being removed. The main ring gear can be seen in the photo, which
is the rusty circular ring. The toothed section in the ring gear rotates, whilst
the ring itself is bolted to the pipe. The teeth being driven on roller bearings
by the screw jacks in the photo.
Above ring gear is removed from the pipe for freeing off.
The ring had to be soaked in a diesel bath for 4 weeks, then heated and teased
with a dog drive gradually, until the inner teeth moved freely.
The dog drive attachment being used to "tease"
the ring free over weeks of repeated soaking and heating.
2 out of 9 screw jacks seized up and requiring
cleaning/freeing/greasing with high temp never seize
22 years of neglect and weathering......
Pipe at advanced stage of rebuild. Freed ring gear and
screw jacks being re-installed.
Gear, rollers, screw jacks all going back together
Reheat bays cleaned, treated with High temp paint.
A close up of our nice clean reheat bays. They won't stay
like that for long!
VARIOUS WORKS
Leading edge panels repainted before re-fitting.
re-fitting leading edge panels after component check and replacement fuel vent
valves.
Lightning Smiths fuel system test set. This little gem is
a must for diagnosing and fixing fuel indication issues.
A very busy looking 579, de-fuelled and in the throws of
exhaustive strip.
A once immaculate machine, before they were left to die at Warton.
A poor quality shot, but proof that the English Electric
Lighting is indeed an all weather machine!
OVERVIEW OF WORK CARRIED OUT BETWEEN MARCH08-NOVEMBER08
Re-build, testing and installation of Dowty Rotol Air Turbine shut down valve.
Removal and repair of lower reheat pipe telescopic cooling ducts.
Overhaul of surface finish to reheat bay internal skins
replacement of all reheat fuel pipe P clips and bonding leads
All steel fastenings in reheat and inter space bays treated with phosphate solution inhibitor, for long term protection
Removal of reheat time delay units for testing and overhaul on test set
Overhaul and reinstallation of ADE383 Dowty Rotol Air Turbine Gearbox. Tested
Removal and repair of broken number 2 engine bay combustion chamber skin drain.
All throttle rods split pinned and roller cages serviced.
Inboard trailing edge pipe fairleads fitted
Starboard main leg brake lines and walking joints re-furbished, fitted and tested.
Main wheel brakes tested.
Fuel indication gauge amplifiers calibrated with Smiths test set
Services and Controls 1 hydraulic leak checks carried out
Ailerons, Stabs and Rudder tested for full and free deflections
Reheat pipes taken apart and refurbishment commenced
Starboard leading edge fuel transfer pump failed on amperage consumption. Pump replaced with serviceable item from XP693
All reheat bay heat shields fully treated and coated with long term high temp paint. Re-fitted.
Leading edges re-painted
All leading edge screws replaced with freshly electroplated screws.
Reheat pipe ancillary spares and wing fueldraulic boost pump Saudi stock spares acquired
Canopy demister motor returned from overhaul J Booker, To be fitted.
AC supplies control circuitry checks begun
Pressure test kit for HP?LP switches and Avpin control boxes acquired
Inter space fire bottles checked.
Interspace inspections complete
No1 interspace pipe inspected, ready for re-fitting.
Both main wing tanks de-fuelled for reference bay fungal checks. completed
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.
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
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.
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!!