L45-010 Shell (24-Feb)

Welcome to the construction page of my L45-010 fuselage

Thanks to Ron Rollo of PROJECT45 the Lear 45 simulator builder can have a new touch of realism. If you are interested in purchasing your very own kit please contact Ron at PROJECT45 for more info. The kit I believe will me take around 6months to complete from Shell arrival to fully built and painted.

The photo above is the the property of PROJECT45 showing the shell halfway completed please keep an eye out for new pictures of his project on Hangar45.net

Please stay tuned for more news and photos. Below you will see how everything is cut out and boxed for shipping.

Shell Building

By referencing the SAM (Shell Assembly Manual located at Hanger45.net in the resource's section) you will be able to follow along with the building steps I am doing.

*You must be a subscribing member to view and download the SAM*

The Base: 14-Feb-2011

Here you can see the base and the SAM awaiting arrival. Shell is in transit.

Drop off! 17-Feb-2011

R&L Delivered on time! Florida to Houston, Texas in 3 days! Nice job..

Getting Started: Unpacking

Opened up the shipping box Ron fabricated and laid out all items. Look at the attention to detail that goes into packing, now your getting the idea how great this kit is.

Hardware

Here is the assembly hardware. In this picture you will notice the TQ Kit and the Floor Kit these do not come with the base shell kit, so when you place your order please speak to Ron about adding in these items.

Just want to thank Ron's Father "Mr. Rollo" for excellent job on all the assembly hardware, there is a lot in it! ;)

Organizing and routing all the Pre drilled holes.

I laid out Port and Starboard pieces the routed all pre-drilled holes.

Phase 1 : Temporarily Assembling the Kit. 18-Feb-11

Here I have begun the assembly of the kit as explained in section 1 of the SAM. Both Port and Starboard Raised Floor section are built.

Port Side

Now I have begun the assembly of the shell itself. Port side completed in 45 minutes. All fit perfectly I might add.

Starboard Side

You can see here both Starboard and Port sides are completed. Again all items fit perfectly. After completing both sides, I installed all the screws at the bottom.

Phase 2: Bolting the Main Frame Parts to Prevent Splitting.

Ron has devised a way to help minimize the splitting effect that screw have on the soft wood. The SAM will explain in more detail, make sure your having a look.

Here you can see the Framing completed and all bolts installed to prevent splitting. Notice the interior also is installed for a test fit, all fits good!

Have a look in the Interior Section of my site for more detail on the assembly of the interior sections.

Phase 3: Notching and Sanding 20-Feb-11

Today I begun phase 3. Notching and sanding. This is when you know your crazy about this hobby, cause if you weren't you would give up. This process takes patience and alot of it, also needs to be perfect casue this portion is the foundation for the fiberglass work.

Photo shows the starboard side completed and ready for prime and paint, tomorrow brings the port side.

Port Side Notching and Shaving completed. 21-Feb-11

Here you can see both sides have phase 3 completed and ready for breakdown to begin the painting.

Prime and Paint..

Below you can see the shell in Primer White, I used KILZ brand white oil base primer. The next photo you can see I had Lowes mix me up some Green oil based Latex (see photo for mixing).

Next will be to install the Aluminum flashing on the inside of the shell to hold all the foam required fro fiberglass.

The Lear45Project for FSX