The Dr.1 kit is progressing at a steady pace. The CAD solid-model is about 85% complete as
can be seen in the image. There are
details left to add, but all the major structures are there. This virtual model serves to make drawings for
make sample parts, suppliers to make final parts, and provides images for the
final plans. 
I have the first mockup of the fuselage as shown in the
photo. You can compare it to the
exploded view from the CAD system in the previous blog and see that it is
coming together as planned. The model
only has a couple of the bracing wires and the turnbuckles on those are too
large. I am now making final parts to
send to the casting company so they can make molds for the kit. They have already made some test parts so we
know that the fuselage will look very realistic and true. These parts will be
made of Britannia metal (similar to Pewter) or Zinc and assembled in a wooden
jig to assure alignment. 
On the engine, I am using the CAD solid-model to send files
to companies that do 3-D printing. They
take the solid-model and “print” the part with thin layers of plastic. The photo shows the plastic model of the carburetor. Actually, the part shown is wrong as the
first couple of parts I sent to get 3-D printed were a factor of 2.54 too large
– a mix-up in the program between inches and centimeters. I now have that under control. I will be using 3_D printing for the parts
that are very detailed and hard to make.
I will send the plastic parts to the casting company to make molds.
I have now built the first wing from sample laser cut
parts. It is a lower wing. It goes together fairly easily and looks right. The sample shown in the picture only has one
cap strip on it and is missing some other details, but is essentially all
there. Don’t judge the workmanship, on
the early models neatness does not count, just the fit and ease of
assembly. I didn't even bother to clean
the laser burn residue off the parts.
Finally, I have the plans partly written (13 pages). They will be rich in drawings and
photographs. Over the summer I will
complete the CAD model, and the first physical models of the fuselage, landing
gear, engine and wings. This will leave
the cockpit details, the tail feathers and the directions for the Fall and
Winter. This kit is on schedule to be
out next Spring.
