Building the OTW Type VII Conning Tower (Part 3)

11/17/05 - Details, details… the seats that came with the model had the support bar molded in to it. I tried to CA glue one in place but a short time later I accidentally hit it and it broke free. So I drilled .020 holes into the middle bar and inserted a brass rod as the support bar. Now the CA glue has more to bite to. I also made the HF antenna mounts and secured them to the Wintergarden rails with a brass rod. The flagpole is from the old 32nd Parallel model – it was a bit over size for the model so I fastened it into my drill and filed it down. The swastika topper is from a scrap piece of brass secured by solder. Weathering has started with a bit of black and brown oil paint thin down with turpentine. Additional dry brushing with silver, black and white will be added.
 
11/28/05 - Have you ever had one of those days.  I did. Last time I used the CA de-bonder I guess there was a high pressure system in the area. When I unscrewed the cap - spurt - several drops shot out of the plastic bottled as if it was under pressure. Well Murphy's Law in full force and the drops ended up on the conning tower. After hosing down the tower the damage was revealed, one drop landed on the wind deflector and the other two on the deck. A few chose words and a day later the mistake corrected and the vents screens are installed.
Started weathering the model. I wanted a subtle washed and weathered look - a bit of rust and a bit of dirt. The goal was to show wear and tear and try not to make it look like the tower is all rusted. I used a combination of pastels chalks and oil paints to create the look. First a coat of pastels chalks were applied. After that had setup a thin down coat of gloss was applied. Then a wash of oils were wiped on.  A mixture of black, browns, and greens oil paints were used for the dark wash. A mixture of brown, crimson, and raw sienna was used for the rust. 
 
Almost there.
 
I cleaned out the lower hull. To remove the lead shot used as ballast I had to take a hammer and chisel to the epoxy. Other areas were cleaned up using my Dremmel with the cable extension and a 60 Grit sanding drum. Once I remove the previous build and got down to the original material I was able to take the next step and try to figure out where all these brass parts go.

I placed the propeller housing to the hull just under the real keel and found that the 32nd Parallel boat’s keel was smaller and the brass housing wasn’t fitting correctly. With measurements I compared the 32nd Parallel’s keel to the plans I had made in 1/32 scale. Sure enough, the keel was about ¼ inch too low and about 2 inches too short. Along with the damage and the pervious build it was simpler to make a new rear keel area. I built up the keel area with Popsicle sticks the rapped it with masking tape. I sprayed the rear area with photo mount adhesive spray and stuck clear plastic wrap to the hull. I then smeared some petroleum grease over the wrap and then laid down the resin and fiberglass. The next day I had what I was looking for.

I then cut out the old keel and cleaned up the area. Feathered down the hull area and the new keel. Set in two indexing pins and wiped down the area with MEK. Mixed up a batch of West resin epoxy and glued the new keel in place. After that was dry I went back and added some more cloth to the area and feathered the joint. A bit more sanding and it will be ready for some holes.
Although a very unorthodox way of making a copy, it was quite effective.
 
I didn’t like the way I made the prop shaft exits – I more or less copied 32nd Parallel’s exits. So I chopped it all off, smoothed over the hull, but left the prop shaft brass tube exists that I had meticulously place to guide the prop shaft. I then made a clay sculpture of what I wanted the exits to look like – idea taken from the “zum Modell” book. I then glued them in place with a drop of CA glue. I used the previous place brass tube to as a guide for the drill to align the exit hole. I then “broke” the piece away and finished drilling out the hole. I enlarged the hole placed a brass tube that was .010 (.168 ID purchased from PSME) larger onto the prop shaft. Aligned everything and CA glued and then epoxy everything in place. 
I took the rudder support and removed it’s pins drilled new holes and inserted #4-40 screws then removed the heads. Took my laser level, made sure the table was level, and placed the rudder making sure it was vertical. The brass supports for the rudder were fabricated from a brass eyelet inserted into a brass tube then over brass rod. I secured the rudder support and solder the brass supports to the rudder support using my micro torch. 
Here the brass support have just been solder to the rudder support. The rear hydroplanes are secure from underneath using a #4-40 set screw. The propeller shaft bracket was counter sunk, #4-40 nuts were epoxy inside and #4-40 flat head screws are used to secure it in place. This makes the entire rear completely serviceable. Every item can be removed, adjusted/repaired and then reassembled. I like it.
The aft hydroplanes don’t line up with the propeller shaft bracket. The propeller “dunce cap” gets in the way. I made a couple of e-mails to Jeff LaRue and Bob Dimmack and the easiest way to correct that problem is to trim the aft hydroplanes. Several people have installed the planes further back and forgone any modification. To me that just doesn't look right. The aft hydroplanes line up with the prop supports. So me being stubborn, from the first time I saw the propellers I thought the “dunce cap” was too pronounced. So I took the hard way and filed off the dunce cap.
 
The bow area was plainly drilled with holes to simulate the vents. I started to open up the holes only to discover two things wrong. One was way too many air pockets in the bow section fiberglass, and two, the previous construction material used did not allow for clean holes. Each hole was very fuzzy. So I made a template out of sheet styrene – cast up a mold – and made the new vents out of resin, CA and epoxy them in, then sanded smooth. An idea from Bill Lambing helped with the hydroplane fairing. The insert tabs were a bit long so I trimmed them down – drilled a hole – tapped it and inserted a #4-40 screw. The nut is soldered onto two washers.
I used my Visio program to draw up a template of flood holes for the stern area. Flipped horizontally, and now I have both left and right. I glued the template in place with spray adhesive and drilled out the holes. This is a lot easier then scribing each hole. If you use the right adhesive the template stays in place even though drilling & filing.  Ahhh... Much better.
 
The hull had a lot of outward spring in it. So much that the upper hull fell into the lower hull. To remove the spring and draw the lower hull inward a hole was dilled slightly larger that a piece of threaded rod. A nut at one end and a wing nut at the other were inserted. As the wing nut was tightened the hull drew inward. Afterwards Celluclay was mixed and placed inside the hull. This gave me an exact template of the inner hull. The template was used to outline a ¼” thick piece of clear polycarbonate to make the bulkhead. A series of notches were cut into the bulkhead, holes were drilled through the hull, counter sunk, and brass screws then attached the hull to the bulkhead. Afterwards, resin epoxy was added to complete the attachment.
On the original 32nd Parallel hull the saddle tanks had individual inlet valve. Unfortunately, some were installed upside down and crooked. I removed all of them, made a casting of four grouped together on a raised panel. Duplicated them, and CA glued them to the hull. This ensured a uniform look and fit. Because the hull is so solid, and only a small portion of flood holes exist, I placed seven ½” holes at the very bottom of the keel to allow addition water flow.
The front fairings of the prototype have a protection cable attach to them. I CA glued a stainless steel cable that I purchased at PSME to each fairing and made a loop in it retained by a small brass tube. The loop of the cable is held tight to the hull via a brass hook fashioned from a fishing line bobber. Inside the hull is a styrene tube with the black top and spring from the bob. Depress the button – the hook extends – and the cable hook is easily attached or removed. Thus allowing for a complete dismantling of all hull pieces.