A simulated maintenance access hatch was
created using automotive aluminum foil tape.
Rudder and elevator corrugations.
hardware store brass hinges, but without
hinge pins so the hatch can easily be
removed and the paint won’t bind the
hinge. The wing nuts were fabricated by
soldering a #2 washer onto the head of a
#2 screw, and then grinding off the part
that did not look like a wing nut.
Fuselage Panel Lines
The techniques used for the panel lines
on the fuselage were the same as those
used on the wing. The main challenge was
marking the vertical lines for the panel
lines and rivets at the bulkheads. The
bulkhead locations were identified by data
in the illustrated parts manual.
I mounted the fuselage vertically on
my kitchen table (not enough head
room in the shop) and used a trammel to
mark the lines by rotating the fuselage.
The cowls were detailed by adding
small screws. Number 1 screws were a
close match for the Dzus fasteners on
the prototype. Number 2 screws were
used to mount the cowl. A hinge was
simulated on the rear cowl by gluing
on a small styrene rod and notching it
with a fine saw. Simulated cowl latches
were made from aluminum sheet and
mounted on a block of plywood in a
cutout in the cowl.
Reinforcing Plates and Repair Patches
A number of reinforcing plates,
maintenance access hatches, and repair
patches were added to the fuselage
after the panel lines. The materials used
to detail the wing were also used here,
including thin styrene sheet, aluminum
foil tape, and small screws.
Doors, Door Hinges, Handles,
Each of the doors opens. Cast-resin
scale hinges were provided in the kit and
can be seen in the included photos. The
door handles on each of the prototype
doors are different. The latch mechanism
and door handles were fabricated with
bits of brass and brass tube. A piece of
3/32-inch square tubing transfers the door
handle rotation through the door to the
The doors are 1/8-inch light plywood,
with a 1/4-inch balsa frame on the inside
to enclose the latch mechanism and
window glazing. A rabbet was routed
around the inside edges of the door
and the window openings to reduce
the apparent thickness. The 0.03 clear
plastic windows are set into the rabbet.
The inside of the front door is skinned
with 0.01 aluminum, and the inner skin
on the rear doors is 1/64-inch plywood.
Passenger Door Steps
The rear passenger door steps
required careful measurements from
the documentation. The steps were
fabricated from brass tube soldered
together in a jig. Some of the tubes were
partially flattened in a vice to create the
oval cross-section. They are mounted
to the fuselage with brass #1 lag bolts
screwed into a 1/4-inch dowel set into
Tail Surface Corrugations
The tail surface corrugations were
made using the same technique that was
used for the aileron and flap corrugations.
Landing Gear and
The landing gear
has been modified
to include the stub
axle on the inside of
the landing gear and
the ski attachment loop.
The axle was altered to
have a threaded end so that a more
scalelike acorn nut could be used to
retain the wheel. This was done by
shortening the end of the original 7/32-
inch outside diameter landing gear
wire, then sliding a 1/4-inch diameter
brass tube over it. The tube was slotted
roughly half of its length so that it
extended to the inside. The inside part of
the tube was reinforced over the slot by
larger tubing soldered into place. A short
length of threaded rod was soldered into
the outer end of the 1/4-inch tube.
The wheels and hubs are from
Glennis Aircraft. The brake disc is from
0.04-inch aluminum sheet. The brake
caliper assembly on the Beaver sits
mostly inside of the hub.
First, a prototype assembly was made
from sheet styrene and brass screws,
then a mold was made and the final
parts were cast using a polyurethane
casting compound. The cast parts are
lighter and stronger than the prototype.
Internally, the landing gear fairing
supplied in the kit contains an
aluminum hinge plate and formed piano
wire struts. These connect through a
hinge pin to 1/4-inch aluminum plates
built into the fuselage, and to a rubber
shock-absorber system similar to what
was used on the prototype.
Externally, the landing gear fairing was
fitted with one disc step and one step
bar. The disc step was fabricated from
a hardware store picture hanger. Most
Beavers have two disc steps, but the
C-FFHB was different. Panel lines and
rivets were added, as was a simulated
The hydraulic hose was made from a
combination of 1/16-inch music wire, 3/32-
inch brass tube, 1/8-inch aluminum tube,
insulation from 16-gauge wire, #2 x 1/4-
inch brass lag bolts, and #1-72 brass nuts.
Antennae and Other Small
A number of small components
are found on the prototype. Some of
these were scaled from photographs
and some measured on the prototype.
The trim-tab rods on the rudder and
elevators were made from rod, wire,
and small ball joints, and are mounted
on tabs made from .01-inch aluminum.
There are two attachment plates on
the bottom that are used when floats
52 Model Aviation APRIL 2017 www.ModelAviation.com