Sikorsky H-19 Restoration - Connecticut Air & Space Center

[Cherrybomber13]

I wanted to take you guys through the process of a quick project we recently did at the shop. With our open hose about to happen we took a hard look at the collection. We agreed that our Sikorsky H-19 had been seen several years ago but noting had been done on it. With a small museum it is hard to get people to understand that our few aircraft aren’t all restored and pretty. Reality is, not enough resources.

The goal here was to add some wow factor to the display but in doing so we realized how quickly this bird could come back together for display. And so we begin...


Sikorsky H-19 note the damage to the port side door. This is from sitting in salt air for about 10 yeeras with no preservatives applies to the exterior.


Sikorsky H-19 Engine Clamshell Door was a spare that was sourced from Arizona many years ago. It was in dire need of stripping and cleaning.



The Sikorsky H-19 Engine Clamshell Door somehow obtained what looks like a bullet hole. At least that’s what we are thinking. It will have to be addressed


First thing first. Markings were transferred to onion skin.


Another view of the replacement door.


The H-19 Engine Clamshell Door after being stripped with AC Stripper. It was then mildly sanded in some areas with 220 then over all with 320 & 400


The H-19 door was previously painted so I did 2 coats of primer, this is the first.




This is the first coat of silver. I traces out the Star & Bar and dusted the paint around the edges.


Our intrepid sheet metal guy Rich Jersey models the scale of the hole in the door.


The door has a scab patch applied. Meaning there is a patch on each side of the hole.


Scab Patch shown from the rear side.


The final patch riveted and primed.


Exhust ring taped up and prepped for paint.


The Star is laid out, tapped and the white coat is added. Bob Bracci, took over at this point with the taping and painting.


Continued painting of the star. Almost finished.


Finished and hung back on the H-19 in time for the open house!


Side view of the door.


Bob Bracci & Drew King - Bob helped Rich Jersey to apply the patch & painted the star & Bar. Drew stripped the door, painted the door, the exhust ring, and door hardware.

[Fouga23]

Looks great!

[Craig59]

Very nice indeed! The aluminum-magnesium alloy skin of the S-55/H-19/HRS/HO4S series doesn't take kindly to harsh environments as evidenced by your photo. Please keep us helicopter afficianados updated on your progress.

[TAdan]

Nice work. That is a great way to show visitors a before and after comparison.

[JohnB]

Nice work!
Good luck from a huge H-19 fan...

[PinecastleAAF]

Nice job. Always liked the H-19.

[tinbender2]

Interesting patch design.

Lacking an SRM, my first choice would have been a small, circular, flush patch right out of A.C. 43-13-1B. But, I don’t work with magnesium skins very often. Is this patch from a structural repair manual or other approved data? I’m curious to know if there are significant differences in requirements for repairing airframes that are mostly magnesium versus aluminum.

[gary1954]

Interesting patch design.

Lacking an SRM, my first choice would have been a small, circular, flush patch right out of A.C. 43-13-1B. But, I don’t work with magnesium skins very often. Is this patch from a structural repair manual or other approved data? I’m curious to know if there are significant differences in requirements for repairing airframes that are mostly magnesium versus aluminum.

[Cherrybomber13]

I will ask Rich when I see him. I do know that he is the same sheet guy who worked for Lockheed for 20 years as well as worked on the Sikorsky VS-44 so I have never questioned his plans when it came to doing up patches. There may have been some issues with brittleness around the hole. The opposing door appears to be covered with a few large patches near the lower portion. Good question none the less.

[tinbender2]

I was curious why a patch on both sides. Do magnesium structures require more support than 2024T3?, or perhaps the skin is so deteriorated from years of neglect? Maybe a TLAR (that looks about right) patch, for a non-airworthy bird, based on previous repairs?

Anyone here have a lot of structural repair experience on magnesium airframes?

[old iron]

What is the white aircraft to the left of the H.19 in the last photo?

[skymstr02]

What is the white aircraft to the left of the H.19 in the last photo?

Looks like a T-37 to me.

[Jerry O'Neill]

T-37 Tweety is correct!
Jerry

[Cherrybomber13]

Well the next section the the H-19 is under way. I have really come to like this bird and we really want to make her look as nice a s possible. This installment we will show how we repaired the Window frame in the starboard main access door.

Note the lower portion of the window hole by Cherry Bomb Photography, on Flickr


View from the rear by Cherry Bomb Photography, on Flickr


IMG_3702 by Cherry Bomb Photography, on Flickr

The next set of shots show the documentation of paint and markings

IMG_3706 by Cherry Bomb Photography, on Flickr


IMG_3708 by Cherry Bomb Photography, on Flickr


IMG_3707 by Cherry Bomb Photography, on Flickr


IMG_3698 by Cherry Bomb Photography, on Flickr


IMG_3699 by Cherry Bomb Photography, on Flickr


IMG_3701 by Cherry Bomb Photography, on Flickr


IMG_3703 by Cherry Bomb Photography, on Flickr


IMG_3693 by Cherry Bomb Photography, on Flickr

Now for the repair (Rich Jersey and myself)

Drill Out the Rivets

IMG_3733 by Cherry Bomb Photography, on Flickr

Measure 3 times

IMG_3734 by Cherry Bomb Photography, on Flickr

Mark with pencil

IMG_3736 by Cherry Bomb Photography, on Flickr

Shear Madness

IMG_3737 by Cherry Bomb Photography, on Flickr

Back Drill

IMG_3739 by Cherry Bomb Photography, on Flickr

Fitting the panel

IMG_3742 by Cherry Bomb Photography, on Flickr


IMG_3743 by Cherry Bomb Photography, on Flickr

Trimming out the junk

IMG_3746 by Cherry Bomb Photography, on Flickr

Cleaning up the patch area

IMG_3749 by Cherry Bomb Photography, on Flickr

Riveted

IMG_3753 by Cherry Bomb Photography, on Flickr

OK Who Stole the Cherry Max Gun?? SOB

IMG_3754 by Cherry Bomb Photography, on Flickr

The project was halted at this point and will be completed Sat Am. Total Time 3 Hours spent with a great friend (Vietnam Vet, VS-44 Restoration Crew and former C5 Galaxy Load Master) Rich Jersey. Great way to spend the night shift! Total Cost - $0


IMG_3750 by Cherry Bomb Photography, on Flickr

[B 25 C]

Very nice work!