Rebuilding Internal Fuselage Components:
Pioneer Aero’s Jason Harris has worked steadily on rebuilding some of the subassemblies which fit inside the SBD's fuselage. It makes sense to prepare as many of these components ahead of time as possible, as it will speed up the fuselage reassembly process later on.
Radar Receiver Shelf:
One of the items which Harris worked on recently is the rear cockpit shelf which holds the radar receiver and rectifier. This component mounts to the upper rear fuselage right behind the life raft tunnel. Sadly, the original example was too badly corroded to reuse, so Harris remanufactured the entire shelf from scratch.
As this image reveals, the radar receiver and rectifier shelf was riddled with corrosion. As a result, Pioneer Aero remanufactured a new example from scratch. (image via Pioneer Aero Ltd.)
A closeup of the original radar receiver and rectifier shelf revealing the extent of the corrosion. Note the text "61ST". This is a reference to the material properties of the aluminum sheet, which is effectively equivalent to 6061 T6 in modern parlance. (image via Pioneer Aero Ltd.)
The Dauntless's radar receiver and rectifier shelf under remanufacture. Pioneer chose to rebuild this component from 2024-T3 sheet, a stronger alternative to 6061 T6. (image via Pioneer Aero Ltd.)
The radar receiver and rectifier shelf remanufacture getting closer to completion. (image via Pioneer Aero Ltd.)
The newly fabricated shelf on the left alongside the corroded components from the original on the right. (image via Pioneer Aero Ltd.)
The freshly-remanufactured radar receiver & rectifier tray during the riveting process and primer-painting. (image via Pioneer Aero Ltd.)
Gunners Floor:
Harris also spent time working on the floor for the rear gunner’s cockpit. Most of the structural rework for the parts used in this component took place late last year, however they required riveting together, a task which Harris has now completed as far as practical. The floor now awaits test-fitting in the fuselage when that time arrives.
The rear cockpit floor. The parts for this subassembly were restored/refabricated earlier, but still required riveting together, a task which was underway when this image was captured. For reference, the rail in the lower right corner of the image faces the front of the airframe. (image via Pioneer Aero Ltd.)
A close up showing some of the rivets recently shot into the rear gunner compartment’s floor. (image via Pioneer Aero Ltd.)
The mounting bracket which holds the rear control stick while it is stowed on the left hand wall of the aft cockpit. These parts were previously restored/refabricated but awaited riveting, a task which has now occurred. For reference, this part is fitted to the outside of the left rail of the rear cockpit floor. (image via Pioneer Aero Ltd.)
Rudder Pedal Support:
The original rudder pedal support structure in B-22’s cockpit was damaged beyond repair, however a donor airframe was able to supply examples of the same parts in near perfect condition. These parts are under restoration for reuse, and presently in the process of being riveted back together.
The original pilot’s rudder pedal support structure from SBD-5 “B-22” (seen here) suffered significant buckling and cracking during the Dauntless’s WWII accident, along with corrosion damage in subsequent decades. This rendered the parts suitable for informational purposes only. The channel section connecting the two elements forms part of Frame #1, which was completely broken and corroded away from the rest of the frame. (image via Pioneer Aero Ltd.)
Another view of the heavily damaged pilot's rudder pedal support structure from the Museum's SBD-5 Dauntless. (image via Pioneer Aero Ltd.)
Another view of the heavily damaged pilot's rudder pedal support structure from the Museum's SBD-5 Dauntless. (image via Pioneer Aero Ltd.)
An underside view of the SBD pilot’s righthand rudder pedal support structure from a donor aircraft. For reference, the lower edge points towards the front of the aircraft. (image via Pioneer Aero Ltd.)
Another underside view of the SBD pilot’s righthand rudder pedal support structure from a donor aircraft. For reference, the lower edge points towards the rear of the aircraft. (Image via Pioneer Aero Ltd.) (image via Pioneer Aero Ltd.)
A topside view of the SBD pilot’s lefthand rudder pedal support structure from a donor aircraft. For reference, the lower edge points towards the front of the aircraft. (image via Pioneer Aero Ltd.)
Some of the structure from the pilot’s lefthand rudder pedal support structure from a donor aircraft after dismantling, bead blasting, inspection, primer painting. It is shown here during the process of being riveted back together. All these parts are from the donor aircraft. (Image via Pioneer Aero Ltd.)
