Douglas SBD-5 Dauntless

May 5 2009
A Volunteer works on unscrambling the puzzle of parts and drawing making up the vertical fin

Mar 31 2009
The replacement elevator for the right side has been completed.

Mar 10 2009
Since the newly fabricated elevator is moving along, the elevator trim tab is nearing completion.

Feb 24 2009
A Volunteer checks the alignment of ribs and makes small corrections before starting the riveting process.

Feb 3 2009
Piece by piece an experienced Volunteer clones a missing elevator with the help of a damaged but surviving elevator.

Jan 27 2009
One of our experienced metal working volunteers is using one surviving elevator to make replacement for the missing elevator.

Jan 15 2009
Progress is being made on reconstructing the rear fuselage and vertical fin.

Sep 3 2008
The engine and propeller are staged next to the fuselage to be ready for mounting. You can see a recently fabricated rear fuselage bulkhead on the left side of the photo, leaning on the wing.

Aug 23 2008
Before and After restoration engine comparison.

Aug 14 2008
The top portion of a 3 piece engine cowling has been remanufactured.

Jun 3 2008
A staff member is fitting newly fabricated pieces of the vertical fin from vintage drawings.

May 27 2008
Fabrication and fitting of the missing bulkhead is moving along. Some of the complex pieces provide their little challenges for staff and volunteers.

May 20 2008
A staff member has made noticeable progress on replacing the skin on the rear of the fuselage.

May 13 2008
A restoration staff member test fits a replacement skin panel.

Apr 15 2008
Four stringers, brackets and bulkhead extension have been fabricated and installed. You can see the third version of upper fuselage and vertical fin bulked (this version is made of laminated plastic and Styrofoam). Plus any changes the pattern will be used to make the metal bulkhead.

Apr 3 2008
The reverse engineered cardboard bulkhead has been completed. The next step is to make another pattern out of a more rigid material and refine the final design that will be used for the metal layout step.

Mar 29 2008
A new father/son volunteer teams aids in helping make patterns for missing pieces for the SBD.

Mar 18 2008
Three damaged stringers have been fabricated and test mounted to check the fit. The lower fuselage bulkhead on the left side will need an extension piece fabricated.

Mar 15 2008
Good thing this volunteer remembers his engineering classes at the University of Arizona years ago. He is studying copies of original Douglas Aircraft drawings.

Mar 11 2008
The rear bulkhead is now firmly riveted to the tail wheel brackets. In the next few days the rear fuselage will be able to support itself on the tail wheel if needed.

Mar 10 2008
The project's team leader inspects the quality of his riveting.

Mar 8 2008
A volunteer test fits the rear bulkhead at the back of the fuselage. The museum has been able to get a few replacement parts for the aircraft.

Mar 4 2008
Alignment is also checked inside the fuselage with a laser.

Mar 4 2008
You can see the faint red laser line on the two vertical members as they are rechecked for proper alignment. Every change to the tail assembly, tail wheel and rear bulkhead requires a recheck of the alignment.

Feb 23 2008
Work is well under way on the vertical fin an tail wheel mounting. Instillation of parts is only temporary to test fit and alignment. Watch for an increased level of activity in the next several weeks. In the background you see work proceeding on our B-26 wings.

Feb 22 2008
What do you do when you are missing a critical casting? Get a drawing, make a model, test model, call your machinist.

Feb 20 2008
The SBD project leader test assembles part of the vertical stabilizer. Riveting of the structure will not occur until the structure is thourely checked.

Feb 12 2008
A volunteer crawling through the rear fuselage found the tail hook attachment point that has been covered over from the outside.

Feb 7 2008
The tail wheel has been partially assembled to check fit and integrity of parts. When the sheet metal crew gets a little further along we will try a test mount. If you look at the picture below and above of the end of the fuselage you will see the four brackets that it attaches too. New bushings are being made to insure proper fit before mounting.

Feb 2 2008
Cowling for an SBD-5 has been located. Though damaged they are repairable. In one of the sections you can see the slots for the forward .50 cal machine guns and the intake for the carburetor between the gun slots.

Jan 15 2008
The engine is waiting for final inspection. It will be wrapped for protection until the aircraft is ready for mounting of the engine.

Jan 14 2008
A volunteer completes the last of the safety wiring of components prior to inspection by the chief mechanic. Plastic covering is used to protect the engine in its final stages.

Dec 7 2007
A close inspection of the main landing gear looks in good condition and capable of supporting the aircraft. Two new wheels have been machined and are waiting for tires.

Nov 30 2007
The main fuselage section has been cleaned, corrosion protected and moved to the Restoration Hangar to start the project.

Aug 24 2007
The propeller pieces have been clean and cocooned waiting for engine completion and mounting on the airframe. It is easier to store and handle disassembled.

Oct 2 2006
The museum was able to acquire the correct engine and mount for the SBD-5. Then engine department has already surveyed the engine for parts needed and prepared a plan. You wouldn’t have a spare prop governor for a Wright R-1820 would you?

Dec 29 2005
The main fuselage in storage as it awaits its turn in Restoration. Looking at simplicity of design there are only 4 bolts to connect the engine mount to the fuselage (the engine department will be pleased). In the background on the right you see part of a P-40.