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Thunderbird Is GO! Following the historic air racer’s momentous first engine runs with AirCorps Aviation in Bemidji, Minnesota a week or so ago, it was only a matter of time before the Dakota Territory Air Museum’s latest Mustang made its first post-restoration flight, and we are excited to report that is precisely what occurred today. While we await further details, the following report from Chuck Cravens describes the final dash to completion at AirCorps Aviation which saw Thunderbird reclaim its rightful place in the skies…
This is AirCorps Aviation’s second post-restoration first flight in just the past three weeks, with the other being P-47D Thunderbolt 42-27609 (also for the Dakota Territory Air Museum). Veteran warbird pilot, Bernie Vasquez, was at the controls this time too. We should expect to see both of these spectacular, ground-breaking restorations at EAA AirVenture Oshkosh this summer! Congratulations to everyone who made this historic moment happen!!!
Thunderbird has its engine! (photo via AirCorps Aviation)
The overhauled Merlin came in not too long after the airframe’s move to AirCorps’ hangar at Bemidji Regional Airport. But before the move could take place, work on the airframe, scoop, radiator, various fillets, cowling panels, and cockpit had to be completed…
Here is the newly overhauled Merlin V-1650 in place. (photo via AirCorps Aviation)
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Airframe Work
Many details were taken care of as the yet-to-do checklist was shortened before the move to the airport.
The flaps and radiator are visible in this photo.(photo via AirCorps Aviation)
Trim tabs and the control linkages to operate them were completed. (photo via AirCorps Aviation)
Another view of the tail surfaces shows the position of the rudder and elevator trim tabs.(photo via AirCorps Aviation)
Mark Tisler works on trimming a panel.(photo via AirCorps Aviation)
The landing gear
doors look good. (photo via AirCorps Aviation)
A hand pump was used to pressurize the landing gear hydraulics as gear swings were completed.(photo via AirCorps Aviation)
Here is a close-up
of the hand pump. (photo via AirCorps Aviation)
The framework to support the polished “smile” is finished. (photo via AirCorps Aviation)
Mounts are in place and ready for the engine.(photo via AirCorps Aviation)
Gear doors and linkages were finished.(photo via AirCorps Aviation)
The elbow directing intake air to the carburetor is shown here.(photo via AirCorps Aviation)
The pitot tube was
installed in the right wing. (photo via AirCorps Aviation)
Aileron control cables were completed. (photo via AirCorps Aviation)
This is a fuel vent. (photo via AirCorps Aviation)
Scoop & Radiator
The radiator and the scoop that houses it are critical components for reliability in Mustangs.
The radiator section of the scoop sits on a bench before installation. (photo via AirCorps Aviation)
This is a closer view from the other side of the radiator. (photo via AirCorps Aviation)
The radiator has been leak tested and mounted in Thunderbird. (photo via AirCorps Aviation)
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Fillets
The wing and tail fillets on a Mustang are true metal forming artistry and requirer intricate forming of complex curves in the aluminum skin. Randy Carlson came over from his shop, Carlson Metal Shaping in Fargo, to take care of this specialized work.
The wing root fillets look great. (photo via AirCorps Aviation)
Here we see the right-wing root fairings. (photo via AirCorps Aviation)
A rear angle shows the weld that joins the upper and lower left-wing root fairings. (photo via AirCorps Aviation)
Cowling Panels
Another area that requires skilled metal-forming artistry is the fitting of the cowl panels.
Mike Izzo works on one of the upper cowl panels. (photo via AirCorps Aviation)
A lower cowl skin awaits its turn on a workbench. (photo via AirCorps Aviation)
The tight and intricate curves required to fit the cowl skins to the front structure are clear in this shot. (photo via AirCorps Aviation)
The lower right side of the cowl has been completed in this shot with the stainless panel that surrounds the exhaust stacks is clecoed in place for fitting. (photo via AirCorps Aviation)
The skin panel that covers where a Mustang ordinarily has air vent holes leading to the air filters has been completed. The lack oif air holes was part of the effort to reduce drag on this Bendix racer. (photo via AirCorps Aviation)
There’s more fitting work for Mike as the upper nose skin is finished. (photo via AirCorps Aviation)
The prop has been installed and the polished “smile” is visible in this image. (photo via AirCorps Aviation)
Cockpit
A great deal of wiring, hydraulic work, and detailed installation of instruments and controls has to be completed to ready the Thunderbird for flight testing.
Aaron spent a lot of time inside Thunderbird’s cockpit this month. (photo via AirCorps Aviation)
His hard work shows in this image of the partially completed panel. (photo via AirCorps Aviation)
The bracket and jacks for the rear seat intercom are a custom installation. (photo via AirCorps Aviation)
The battery box has been readied for installation. (photo via AirCorps Aviation)
The two batteries are a tight fit in the new box. (photo via AirCorps Aviation)
Neat and organized routing of the wiring harnesses is a painstaking task. (photo via AirCorps Aviation)
Here is the same area after the wiring has been completed. (photo via AirCorps Aviation)
Thunderbird in the shop on May 25th as it nears test flight status. The first engine run was scheduled for this day. (photo via AirCorps Aviation)
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Engine Test Run
The first run of the engine in a new restoration is always exciting. It is like the airplane coming alive.
The Merlin comes alive in a very successful test run. (photo via AirCorps Aviation)
Final preparations are made in the hangar before the test run. (photo via AirCorps Aviation)
Thunderbird is ready. (photo via AirCorps Aviation)
Thunderbird has been rolled outside for the engine test run. (photo via AirCorps Aviation)
Aaron tops off the coolant tank. (photo via AirCorps Aviation)
Mark climbs aboard. (photo via AirCorps Aviation)
Warren Pietsch gets ready to climb into the cockpit to run Thunderbird himself. (photo via AirCorps Aviation)
Warren starts the Merlin. (photo via AirCorps Aviation)
Warren looks pretty pleased with the engine test. (photo via AirCorps Aviation)
Bravo to everyone at AirCorps Aviation for this magnificent restoration and to the team at the Dakota Territory Air Museum for having the vision and perspicacity to back it up!
Richard Mallory Allnutt's aviation passion ignited at the 1974 Farnborough Airshow. Raised in 1970s Britain, he was immersed in WWII aviation lore. Moving to Washington DC, he frequented the Smithsonian’s National Air & Space Museum, meeting aviation legends.
After grad school, Richard worked for Lockheed-Martin but stayed devoted to aviation, volunteering at museums and honing his photography skills. In 2013, he became the founding editor of Warbirds News, now Vintage Aviation News. With around 800 articles written, he focuses on supporting grassroots aviation groups.
Richard values the connections made in the aviation community and is proud to help grow Vintage Aviation News.