MVP F86F Sabre Sim Pit - Build Blog

[[MVP] Mugga]

In parallel to the F86 SIm Pit build using all original hardware, [MVP] IndianaShane is working to create detailed replica hardware and has spent some time designing an ejection seat that can be constructed out of plywood and MDF.  A major advantage in designing replica units is having access to original items so that they can be duplicated in detail.  Whilst the replica design below is in an early prototyping stage, it is looking fantastic and will provide a pathway for others who may be seeking to build an F86F Sabre pit for their DCS World flying fun!  As mentioned in the posts above, we intend on launching a web-store where interested persons can purchase replica seats, accessories, cockpit items and more.

 

 

 

[[MVP] Mugga]

The F86 sim pit project is still alive!  Have managed to track down an original CAC CA27 Sabre airframe and am currently negotiating to purchase it so that I can convert it into the ultimate DCS World F86 Sabre Sim Pit!  More photos to follow as things progress.

 

Edited March 25, 2023 by [MVP] Mugga

[Spitty]

Western Australia?

[[MVP] Mugga]

Jagged myself an original F86F Sabre rudder pedal and arm assembly this evening.  Another great score for the sim pit build.

 

[[MVP] Mugga]

Great news... after quite a few months of back and forth negotiations, I have been successful in closing out a deal to acquire ex-RAAF CAC CA27 Mk32 Sabre for conversion into the MVP Sabre Sim Pit!  For a while there I thought there was no possible way to get the deal done, but things came together in the end. 

At this stage, the plan will be to move the airframe back to our workshop facilities at YSBK Bankstown Airport in NSW, where we can get stuck into cleaning the airframe out of the accumulated debris etc.  Just moving the airframe is going to be a solid effort, as the property the airframe is located on is very much in the middle of the bush.  The sheer weight of the airframe means we will be needing a serious crane/lift to get it up onto a truck/trailer.

Then I have to work out what I am going to do with all the additional airframe components that are of no use to the sim pit build.  Either way.... what an adventure.
 

 

 

 

[[MVP] Mugga]

This Saturday coming the MVP team are heading back out to the location where the Sabre airframe is stored to work out our recovery and relocation logistics.  The site is approx 45 minutes drive from where we are based and is down a lengthy bush/forest track which is just barely accessible with a 4x4 utility, so some careful planning will need to go into how we get everything out safely.  In addition the forward fuselage section is approx 2.2 tonnes, so we will require a sizeable tractor/crane to safely lift things out and most likely a sizeable tilt-tray truck to load everything onto.  Cannot wait to get everything back to our facilities, where we can give everything a pressure wash and clean down.  I will post more photos and updates after Saturday this week.

[[MVP] Mugga]

The beautiful Sydney weather gave the MVP team the perfect opportunity to get out to the Sabre Jet today to get things organised onsite for a possible move next weekend.  The access road to the property was much worse than what I had remembered from the first visit with some seriously steep inclines and declines to travel along.  Our plan is to bring a tilt-tray truck onsite and to use a 12t Excavator to lift up the sections using load slings.  Worse case scenario, if the tilt tray truck cannot navigate the access track, we will use the excavator to sling-load the airframe components down the access road and load outside of the property.  Given the dimensions of the airframe sections, we will need to do three (3) deliveries to get everything back to Sydney, Bankstown Airport.

[[MVP] Mugga]

Quick update... the big move is planned for this weekend coming with trucks and crane booked.  Saturday 10th, we will load up the fuselage and wings and bring them back into the workshop at YSBK Bankstown Airport in Sydney, where the fun will really begin.  Lots of cleaning up to be done!

Whilst the logistics have been sorted out, a contact of mine has donated a set of USAF F86F Sabre wings to the MVP team.  Not sure what we are going to do with these at this stage, however, they may end up being converted into epic gaming desks!

If anyone has any ideas for what the wings could be used for, post them!

 

[[MVP] Mugga]

The big move day has finally happened and the MVP F86 Sabre has now been relocated into the workshop hangar! 

I honestly thought the team would have been able to move everything in half a day, but ended up going from daylight to dusk.  Thankfully we had access to a 20 tonne excavator on the property, which enabled us to lift everything effortlessly onto the truck.  However, on the workshop end things got a little tricky with just a 1.8 tonne forklift with slippers to unload!  The truck driver came up with an ingenious method of winching the fuselage off the truck, which involved lifting the front of the aircraft from its cannon ports and stacking pallets underneath it, whilst winching everything down the tilt-tray.  Several hearth thumping moments as we almost tipped the forklift over.  In all it took approx. 40 minutes to unload the fuselage, ensuring we did not break anything on the aircraft unnecessarily.

We managed to haul both wings on one load, stacking them on top of each other.  The wings are substantially damaged and corroded, so whilst we took care to not create any further damage, we were not as concerned with moving those.  They are both at the workshop hangar now, and stored outside on pallets.  Both wings will be raised onto stands on Sunday afternoon, so that we can commence stripping the undercarriage, ailerons and accessories out of them.  Both wings are being converted into event and board room tables, which will look immensely cool when they're finished!

We unfortunately ran out of time for the rear fuselage section, which has remained onsite.  It will be picked up next saturday, where it will then make it's way to Western Australia!

With the airframe now in the MVP workshop hangar, we spend a couple of hours starting the external airframe cleaning.

 

[[MVP] Mugga]

I am super pleased with the condition of the fuselage skins, which under all of the grime and dirt are in great condition.  In fact, they're so good that I am contemplating not painting the aircraft in RAAF silver, but instead performing a mirror polish.

[MAXsenna]

Imagine meeting you guys on the road...

Sent from my MAR-LX1A using Tapatalk

[[MVP] Mugga]

The looks from people in the cars around us was awesome!  You could immediately note those who had a genuine interest in aircraft and aviation, as they sped up and took time having a good look.  Then there was those who just drove past and took no notice whatsoever!

 

[MAXsenna]

Mugga" userid="93050"] The looks from people in the cars around us was awesome!  You could immediately note those who had a genuine interest in aircraft and aviation, as they sped up and took time having a good look.  Then there was those who just drove past and took no notice whatsoever!

 

That's awesome!

Sent from my MAR-LX1A using Tapatalk

[[MVP] Mugga]

Back into the workshop hangar today to get stuck into cleaning up the forward fuselage section, along with removing all of the aft plumbing, electrical and mechanical items.

As you can see from the two photos above, everything aft of the main canopy is going to be cut off, shortening the forward fuselage section to a more manageable length.  This means, everything you can see in the back of the aircraft has to be disconnected, so that we can run a 5-inch power-saw around the aircraft!

 

Whilst a friend of mine was busy inside the back-end of the fuselage, I spent some time trying to remove some of the extremely corroded panels.  The aluminium has suffered what is called "inter-granular corrosion" which causes the metal to separate into thin layers... much like a pile of paper.  As the panel exfoliates, it swells up and then applies significant pressure and stress to the structure around it, which in turns creates further damage.

 

 

 

Unfortunately, the airframe was stored outside for the past 40 years and during this time, just about all of the steel bolts and hardware have rusted badly, making removing things very difficult.  The Ryobi angle grinder made short work of anything that refused to budge.

 

 

 

[[MVP] Mugga]

The next series of photos are the main canopy which was removed to give full access to the cockpit for cleaning and restoration.  The frame is in average condition and the perspex is heavily damaged.  I do have another canopy frame and between the two I am certain I can construct a good one!

 

 

The next series of photos are just to demonstrate the condition of the fuselage skins.  whilst they look good, there are areas on them that are corroding.  The main fuselage centre section is assembled using steel monel rivets, which with time react with the aluminum skin and corrode.  Where this happens, it bubbles up.

 

 

 

 

The above series of photos are just to demonstrate the condition of the fuselage skins.  whilst they look good, there are areas on them that are corroding.  The main fuselage centre section is assembled using steel monel rivets, which with time react with the aluminum skin and corrode.  Where this happens, it bubbles up.

 

 

 

 

[[MVP] Mugga]

Some interior cockpit photos showing the condition inside it.  The last job I got to this evening was to start clearing out the years of dirt, leaves and other crap from inside with the shop vac.  The next step is to the get the pressure washer in there and to blast it all out, so that it can all be prepared for a new coat of primer paint.

 

 

 

 

Today we tackled the ‘big cut’ of the forward fuselage section, removing approx 1.8m from the aft end. We had originally hoped to use a 9-inch cutter, but elected to use a smaller 4-inch to get into all the tight places. Yesterday we removed all of the internal plumbing and equipment that connected the cut line, so today it was an exercise of simply cutting through the structure and carefully moving the section away.

 

 

We successfully removed the aft section of the forward fuselage today, having spent the evening yesterday disconnecting all internal plumbing and wiring in the area of the cut line. The forklift proved to be an immensely useful resource, being able to neatly tilt the lifting tines forward and evenly under the tail section.

 

 

The next step in the journey is to fabricate and attach a suitable rolling stand. There has been much debate in the workshop today as to how we should approach a solution. One suggestion is that we fabricate a rear stand mounted off the centre section, and using the nosegear for the front. This would enable the unit to be towed around etc, but introduces additional height which will make sim cockpit harder to operate.

 

 

Edited June 12, 2023 by [MVP] Mugga

[[MVP] Mugga]

Took some time this evening to mock up the external scheme that will be applied to the cockpit section!

 

[MAXsenna]

This project really deserves a YouTube channel!
Does it have one?

Cheers!

Sent from my MAR-LX1A using Tapatalk

[Spitty]

Ex QANTAS tin basher here.Feel the pain...

[[MVP] Mugga]

30 minutes ago, Spitty said:

Ex QANTAS tin basher here.Feel the pain...

Are you Sydney based mate?

[Spitty]

13 hours ago, [MVP] Mugga said:

Are you Sydney based mate?

Nah Im just north of Brissy.

[[MVP] Mugga]

Managed to squeeze in some time today, getting stuck into the cockpit and windscreen assembly.  The quarter glass panels in the forward windscreen assembly on A94-965 were removed, in preparation for de-riveting the assembly from the aircraft.  The windscreen structure and skins are badly corroded and will be replaced with a NOS production spare that was acquired and is held in our parts store.  The unit removed from the aircraft will be sold off.

The instrument panel glare-shield was also removed from A94-965 today.  This unit will be disassembled to components and everything given a fresh coat of paint, then reassembled.  All new placards will be applied.  The glare-shield will then be installed into the production spare front windshield assembly for re-installation onto 965.

 

[Spitty]

Looks like the electrical connectors are British WW2.Probably left over stock from CAC.

[[MVP] Mugga]

We managed to get the upper nose cowling removed from the Sabre today to give us an idea as to what is still installed.  The plan is to remove all of the original avionics and electrical items, leaving the entire compartment empty.  A few of the boys at the workshop today suggested that we install a fridge and ice-maker for cold beers and cocktails, others suggested installing a set of DJ decks, or a sound system.  All good suggestions.

The team were back onsite Saturday to get the rear fuselage section dismantled and loaded onto the transport trailer, where it will now be road-transported to Western Australia. The horizontal tail-plane, fin, rudder and speed-brake assemblies will be used as part of a Canadair Mk6 Sabre restoration. A big shout out to the MVP team for their efforts this weekend!

 

Edited June 19, 2023 by [MVP] Mugga

[Vinc_Vega]

I'd like the cold beer option.

Regards, Vinc