Hughes H1 Racer Repairs

Home > Gallery of Metalwork > Aircraft Metal Work > Hughes H1 Racer Repairs


Loading
  • Hughes H1 Racer Repairs

    This is Jim Wright, owner/builder of the Hughes H1-Racer replica (the only replica ever built to date of Howard Hughes famous aircraft because of the complexity of the plane’s design). Jim encountered a gear failure during a landing which led to a crunched wingtip and tail. Since I had done the initial fab on the tail section, Jim called me for the repair work.

  • Hughes H1 Racer Repairs

    The tail was displaced 4 inches to the right. Due to the development methods employed by the builders, we could save three month's time if I could straighten the parts I had made previously. ICK.

  • Hughes H1 Racer Repairs

    Tail assembly cleared of mechanicals, airframe secured, and I am ready to start.

  • Hughes H1 Racer Repairs

    Where to begin?

  • Hughes H1 Racer Repairs

    Pull off the tail as an assembly and lay it on the bench.

  • Hughes H1 Racer Repairs

    Tools needed for straightening:

    • 3 small double wall shot bags
    • Spring steel spoon & Spring steel slapper
      (note the difference between these tools)
    • Cross-pein body hammer
    • Double-faced deep reach body hammer
    • Dead-blow cross-pein with 3 removable faces
    • Straight edge
  • Hughes H1 Racer Repairs

    Large shot bags are used to stabilize the tail.

  • Hughes H1 Racer Repairs

    Compressive working shifts the aluminum without stretching. A small shot bag used as a “soft” dolly.

  • Hughes H1 Racer Repairs

    Carefully, gently and analyzing each and every whack, the damage is sorted out.

  • Hughes H1 Racer Repairs

    I am working down the high spots and working up the low ones.

  • Hughes H1 Racer Repairs

    Step by step, making sure there are no mistakes, each and every wrinkle is dealt with in order. This process of reversing the order of damage is traditional to the best repairmen. Sometimes one wrinkle must precede another, also known as "unlocking" the damage. The trick is never to assume but always to analyze, measure, and calculate.

  • Hughes H1 Racer Repairs

    Jim holds the tail while we check for strain.

  • Hughes H1 Racer Repairs

    Missing piece must be fabricated.

  • Hughes H1 Racer Repairs

    Finished job shows no evidence of damage. 400 grit sandpaper was used sparingly to highlight the last imperfections. It polished perfectly. NO ONE ever noticed the airplane had ever been damaged. My time: 14 hours (3-month delay averted).