On display at Wright Patterson AFB, Dayton, Ohio
The Morane Saulnier AI being built at the Kansas City AIM Campus attracted a lot of attention this weekend at the Air Force Museum in Dayton, OH. The three-day World War I Dawn Patrol Rendezvous takes place every other year on the back field of the National Museum of the United States Air Force. It is presented by the museum and the Great War Aeroplanes Association.
While not yet complete, the aircraft was trucked to the site and assembled by students eager to share their craftsmanship. Between the rare nature of the aircraft, and the authentic but colorful paint scheme, it was easy to pick out of the crowd.
We also want to acknowledge the enthusiastic crew of students and instructors that made this show work. Here is the gang, and they have made it real easy to pick out the instructors. From left to right below are: Tim Fisher, James Bennet, Dan Brown, James Shoemaker, Jesse Sutton, Chris Hendrix, Derrick Sutton, Bill McMahon.
The Kansas City crew took full advantage of the weekend, and spent a lot of time talking with the public, other visitors, and the students from the AIM Indianapolis who also brought their Word War I aircraft project for display. There was also time for a quick tour of the Air Force Museum, and the restoration shops which are not normally open to the public.
The airplane is back home in Kansas City today, and will begin the final assembly process which includes the installation of a new, larger, fuel tank and plumbing to the fuel and oil systems for the engine. There are a host of small details to be worked on, but I suspect the enthusiasm gained from this weekend will help those jobs move along at a much faster pace.
World War One Airshow
October 7-9, 2011
Revisit aviation history during World War One at the Military Aviation Museum!
- Watch our rare WW1 warbirds in flight & static displays
- Talk with the re-enactors
- Vehicles, armor, and artillery demos
- Vendors & military flea market
- Meet enthusiast and collectors
- Ride in an open cockpit biplane
More information
World War One Airshow
Telephone (757-721-7767)
Sherri Sharp-Folson applying reinforcements to ribs on wing.
Robert Leming using plasma cutter cutting bracket for the side forms 
Chief Builders Rich Ellis and Al Moore discussing the blueprints for the wing on the Nieuport 11 
Sherri Sharp-Folson Sanding pieces of reinforced wood for ribs on wing
- The fabric is on the bottom surface of the wing, and the top is ready to cover.
- Under the watchful eye of Project Manager Marvin Story, the students position the fabric on the wings upper surface.
After what seems like an eternity of dealing with the details, we are finally getting fabric on the wings of the Morane. In an effort led by students Timothy Fisher and James Shumaker, the wings have fabric now and they are busy getting it secured in place and looking forward to the formidable task of rib stiches, by the hundreds!
With the completion of the wooden leading edges, the wings are ready for cover. We hope to get that project started in the next few days. We have had to do some research on how to cover a wing where the trailing edge is made of wire, and not solid like more modern aircraft. Then we are faced with taking the way it was done in WWI and translating that for modern materials. We are covering with Dacron instead of cotton or linen, so a few changes are in order.
A big thanks to Denise Crall for the photo’s. Denise was one of the original group of students who launched this project and she still comes in from Iowa to check on it’s progress somewhat regularly.
Builder Al and Shannon, from Recruiting.
In all her Glory!
Lead Builder Rich, admiring his Creation.
Builder Andrew takes the controls.
We took our Nieuport to the annual Mt. Comfort Air Show. Everyone who saw our in-progress airplane was terribly impressed. We can’t wait to show off the finished bird at next year’s show!
Center section fittings welded in place
It has been a busy week for the Strutter, after a few tries we have gotten the center section where we want it and it is welded in place. The spars fit as they are supposed to and now we can start assembling the center section. The frame is getting it’s primer coat this week. The wood portions then will be put back on the frame and we can work on the cockpit areas. Adding the second set of controls has added a bit more work but we think it will a great addition to the aircraft. We continue to make fittings for the wings and ailerons, plus there are a few more ribs to make. Most of those are one or two of a kind that have to be built on the airplane.
While we have been remiss about posting our progress, the Morane AI has been moving steadily toward completion. The fuselage is essentially complete, and covered. The engine has been fitted up and then removed to allow us to make the necessary plumbing connections. The wing has been constructed, but is still not quite ready for cover. The wing was fitted to the fuselage to allow us to get accurate measurement for the bridgework of struts used on this aircraft. The struts have all been been cut and fittings installed, but we have not yet started the wooden streamlining that will eventually go on them.
- Working in the cockpit while the engine is out of the way.
While the engine is off we have been making some changes based on what we have learned so far. Both the oil tank and the fuel tank will be replaced with a newer design. The first oil tank we built did not provide clearance for the proper location of the filler neck, and the capacity was reduced. We have also decided to change the fuel tank design to increase its capacity. While the original capacity may have been enough for combat use, we need a little more fuel to get to fly-ins and show off our work.
The wings were disassembled to allow a final coat of varnish, and to paint all of the metal fittings. They are back together and we are installing the wooden leading edges. Students have expressed amazement at how much difference there is between plywood and laminated wood when it comes time to bend it around the leading edge.
- A look at the bottom of the Morane wing with the wooden leading edge being installed.
The wings are nearly ready to cover, and everyone is getting excited about that project. Hopefully we will get more frequent updates started as this project moves steadily toward completion.