The restoration of the world’s oldest flying Consolidated PBY-5A Catalina, BuNo 2459, is progressing at American Aero Services in New Smyrna Beach, FL. After spending several years in the Netherlands, this iconic U-boat killer has been owned by the American Heritage Museum since 2019. Recently, the American Heritage Museum shared an update on this restoration, which we are publishing here with their permission.
Built on the production line during the attack on Pearl Harbor, BuNo 2459 was one of the first five PBY-5A amphibians ever constructed. Due to hazardous sea conditions off Iceland, the aircraft was immediately assigned to VP-73 upon rolling off the assembly line. Accepted by the U.S. Navy on December 22, 1941, BuNo 2459 became the fourth amphibious PBY delivered to the Navy. It was pressed into service right away, joining VP-73 as aircraft number 9. Notably, it was the first PBY to sink a U-boat.
While the exterior restoration is nearly complete, the interior restoration to return the aircraft to its original 1942 wartime configuration has proven to be a monumental challenge. The restoration crew, led by project manager Casey Littrell, has faced significant hurdles due to the aircraft’s lack of original equipment upon its arrival from Europe. Nearly all of the interior components have had to be sourced or fabricated. Original parts for this early PBY are scarce, making the search for materials a difficult task. Furthermore, recreating items requires finding original drawings or photos, adding yet another layer of complexity to the restoration process.
Several key updates in the restoration can be highlighted as the aircraft continues to take shape. External photos of the PBY reveal the completed antenna array for the early variant of ASV (Air-Surface Vessel) radar, which was installed during its 1942 deployment to Iceland. While these early radar systems resembled clotheslines more than modern radar arrays, they represented the beginning of rapid advancements in airborne radar technology throughout the war. No other surviving WWII warplane, let alone a PBY, has had such an extensive antenna array restored for historical accuracy.
When BuNo 2459 arrived at American Aero Services in 2019, the interior had been modified for passenger flights, featuring seats and other comforts that were not correct for its wartime configuration. The restoration team stripped the interior and began rebuilding it from the ground up. Wartime PBYs were designed for long missions, often lasting 10 to 15 hours, which required minimal but functional accommodations for the crew. One such feature was the midship bunk area, which has now been mostly completed, with only minor equipment details left to install.
Moving through the aircraft, the Flight Engineer’s position in the central wing pylon has been installed. This unique position allowed the Flight Engineer (FE) to sit high above the central compartment, with windows on each side of the pylon, giving them a clear view of the engines. The FE had a dedicated instrument panel and could adjust engine power settings independently of the pilots, providing critical support during flights.
Behind the cockpit lies the radio operator’s station, an essential role for communications and monitoring potential enemy transmissions during maritime patrol missions. Restoring the early radio transmitter, receiver units, and radar systems has been one of the greatest challenges. The fabrication of custom mounts and shelves for these units is still ongoing, but photos of the nearly completed station—complete with a restored spare equipment box—highlight the team’s commitment to historical accuracy.
In the cockpit, a unique instrument has been installed: the Mark 28 Torpedo Director. This detachable analog computing device allowed the pilot to target enemy vessels while compensating for their movement and speed. The engraving on the unit reveals a local connection, as it was originally manufactured by Lundquist Tool & Mfg. Co. of Worcester, MA.
At the front of the aircraft, the bombardier and nose turret compartment has been fully rebuilt. When BuNo 2459 arrived in 2019, this area had been replaced with a streamlined “clipper” nose, but the original wartime configuration is now being restored. The final step will be the installation of removable equipment and supplies that would have been found in the compartment during its service.
The restoration of BuNo 2459 is a remarkable journey that honors the legacy of this iconic aircraft. Vintage Aviation News will continue to follow this extraordinary restoration, sharing updates as the PBY-5A Catalina is brought back to its wartime glory. For more information about the American Heritage Museum, visit www.americanheritagemuseum.org.
