1972 Sikorsky CH-53 GS - wip #2 - the work in palstic and wiring

First I opened the holes to get the external tank mountings fitted 

First sight of the hull 

Every possible lid will be opened 

 

By thinning the plastics at the rear, I opened the compartment rooms 

Then cutting throug the thin areas 

Done 

Building the "shelfs" of the electrical stuff rooms 😄 

The hinges for the lids 

The lid is mounted 

 

Also the door is put in place 

The steps and lids 

Starting with the stingers (or how they are called) / frames of the sides 

 

Fitting to the hull 

On bulk for the lift side, one for the right sight. Each frame part is custom built because the hull wents smaller at the rear 

The inner frames around the rear opening is not that good. 

Sanding it down 

Gluing small frames into the hull 

 

Ecery frame is numbered for the correct location. So I'm still knowing, where to lay my hands on and where I have to put more details to.  

The first frames are test fitting. Like it. 

Building the tool box and a propper wall between the cockpit and cargo area 

 

the horizontal beams / frames are in place 

 

Whoho! A whale sceleton 😄. So far it is not glued in place because I'm not done yet. A lot of more details will be added. 

 

The same procedure on the right side 

 

 

 

First view from the cockpit into the cargo bay 

 

 

 

Still not glued in place 

 

 

 

 

So the frames on the sides are done. Now moving to the rear area. 

 

 

Still numbered the frames 

Nearly done with the big box above the upper flap 

The upper flap mounted to test fitting the parts / frames / box 

Looks good so far 

 

 

 

 

 

 

Now it's time to do the upper frames and heating tubes 

 

 

 

The whole frames in place for another test fitting 

🙂 

 

Yep. This is how I wanted it 

 

The electrical compartments are done too. 

Drilling the first holes for the lights of the cargo area. Starting with the easier part. 

Another openings to prepare for the wiring and switches. For example the left fuel tank thing with main gear 

Starting wiring 

The first try with those wires were a failure. They were to thick and not that flexible. 

Between the brain storming for the wiring I painted the interior in the proper color. 

 

 

Put the painted parts in place. 

 

This is my plan for the wiring. The thing is, that the hull is to pieces (like all aircraft model kits as far as I know) but the lamps have to work together. One switch e.g. has to light up the position lights left, right and in the rear (following light). So I had to think over switches and connectors to put the circuits together, which have to work together. The other thing was to keep in mind, that I want to use 9V power. So I need some resistances 

 

Drawing the wires into the shell. 

Then adding more colors for the details.  

Another lines (fuel lines e.g.) of the helicopter installed 

The electrical things of the cargo area in the bay underneath the cockpit. 

 

First peek 

First lights 

The other led / smd led are in place. 

Following light, loading light, cargo area lights 

Searchlights, landing lights, cockpit lights - not finally installed. Just testing the circuits 

 

Another look under the helicopter and it's lights 

Using a mold to do a copy of the cockpit consoles of the Academy kit 

With the over head console it is much better. 

The wiring is almost done 

The wiring to the rear includes the following light, this res stroboscpe light on the top and the loading l 

The wiring for the position lights and a switch for different circuits 

This thing will be able to give the power to the main rotor blades. The lamps are called "formation lights" 

 

Now it's possible to rotate the main rotor head 360 degrees and more 😄 Three connections: two power lines one ground line 

The rotate thing mounted in place and already wired 

tiny holes for the cables to the main rotor blade tips. 

 

This is the SMD LED for the main rotor blade tip 

 

First curcuit is done (three SMD LED each circuit) 

 

Mounting all main rotor blades. Another test. 

The platina for the anti collision lights (this red stroboscope flashers) 

 

Planning to lightening the dash board 

Overlayed the photo etched part by Eduard. 

Two SMD LED are in place. The connector is installed to. As a reflector I used BMF 

 

 

I printed the decals onto transparent foil to get the instruments transparent 

Building the third seat for the board mechanic guy 

Put it on the seat frame 

 

And it is able to swing it out 90 degrees. 

The hydraulic cylinder for the cargo ramp 

Reflectors for the landing ligts and searchlights 

...in place 

 

Another lightning test 

😄 sweet 

 

 

 

Building some benches 

 

Benches installed 

Opening the intake of the APP 

Also opening the exhaust for the heating system 

Drilling some handles onto the dog house 

 

Adding another handles and little doors for the foot steps 

One problem of the Revell kit is, that the landing gears are made in the position of flight - they are to high. So I shortened them 

Drilling holes for a plastic / styrene axle to keep the nose gear stearable 

done. The main gear 

The main gear is shortened too. The left one how it is in the box, the right on in right hight when the CH-53 sits on the ground. 

See the different? 

Opening the exhaust vor the APP 

Above in the picture how it was 

Mounted in place 

Opening other holes for "fresh air" to the cockpit (cold or to the heating)

And there was a bulb for the external fueling system. The German CH-53 doesn't have those system so I had to remove the bulb on the lower glass. 

Inserting two grilles 

The cockpit has it's consoles and seat belts (Eduard) 

This step is also at the original helicopter for reaching the turbines. Why not using for the switches? 

 

Drilling 112 holes 

Drawing the lines, where rivets ave to be added 

Some antennas were broken in the kit 

Well. Make them both better 😉 

Stupid as I am, I opened the cockpit windows after the hull was together and ready to paint. 

The frames for the cockpit windows 

 

 

Rebuilt the whiper arms and blades including a washing tube 

 

At least I buolt some ground equipment for the base. One of it will include a 9V block battery to support the lights without any connection to high voltage.