The first step is to
have access to the aircraft in which a panel is to be
represented. This sometimes is not possible, so we have to
draw on countless reference books and photos availible.
Measuring the desired panel and scaling it down takes us to
the next step. A drawing is done in
full scale so we can get a good feel for the actual size of
the panel before it is made. In this case we did not have
access to measure an F-22 Raptor (for obvious reasons), so
we managed to get as many images of the F-22's nose from
photos and books on the assembly stages to come up with this
drawing with all the panel lines and rivet hole
placements. At this
stage, it is time to turn the original drawing into a CAD
program. Bernie is real good at this stuff and with the aid
of a slide rule and micrometer, he'll turn the drawing into
a working 3-D model of the parts. He'll then print a disk
and its ready for the parts to be made. Here, Sam
Henderson handles a sheet of .032" aircraft grade aluminum
and is cut to its proper size for the punching
machine. Once the
required blanks are cut and the computer program set, they
are loaded one at a time to be punched out by the FC-1000.
This machine punches out the shapes and holes using dies on
a turret. On the average, it takes approximately 2.5 minutes
to produce the parts. This is how
it looks after the STRIPPIT machine is done. The parts for a
B-24 panel is finished and is degreased, cleaned and
separated out of its blank. Assembly
for the B-24 panel takes about 45 minutes to an hour.
Unfortunatly no aid from machines are used for assembly and
all the rivets are hand placed. Here a B-29 panel is
undergoing assembly. The two halves are joined and riveted
to form our panel. Rivet lines have been hammered as
well. The base coating has
been applied to this P-51 panel and is undergoing the
checkerboard process. Eventually, this will end up as Don
Gentile's P-51B "Shangri-La". For this panel all the
stenciling is drawn in its proper places. Yellow markings
are applied first and when dry, red stars are painted
followed by the yellow swasticas. The 'girl' which is the
focal point of the panel is done last. At the shipping stage
before the panel is wrapped, the data stenciling and
national insignia decal is applied.