Recreating the Wright R-1820-52 “Cyclone” (2)

In this post I will finish my model of the R-1820-52 “Cyclone”. (This is the continuation of the subproject that I started reporting in the previous post). Figure 92‑1 shows the oil sump, used in this engine:

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Figure 92-1 Oil sump in the R-1820-52

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The R-1820 “Cyclone” Versions

I decided to write a post about the first decade of the R-1820 “Cyclone” development (up to the R-1820-60 version, i.e. 1940). This engine was used in many designs from 1930s, and you can find the references to its various models in many technical specifications. However, sometimes it is difficult to determine how such a referenced version looked like! The early models of the “Cyclone” were produced in small batches, so there is less historical photos. Sometimes even the specialists from the museums are misguided: in one of them, you can find a SBD-3 fitted with the engine and the propeller from the SBD-5. My query, which resulted in this article, started with comparison of the R-1820-60 (used in the SBD-5) and the R-1820-52 (used in the SBD-3 and -4). I have found so many differences, that I started to wonder about the engine used in the pre-war SBD-1 and SBD-2. (They used the earlier “Cyclone” version: R-1820-32). The results presented below may be interesting to the modelers who recreate aircraft from this period (for example – the Curtiss “Hawk”, or the Grumman F3F-2 “Flying Barrel”).

Let’s start from the beginning: below you can see the first model of the R-1820 family, designed in 1931 (Figure 90‑1):

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Figure 90-1 One of the earliest R-1820s

Frankly speaking, there is only a general resemblance to the later “Cyclone” versions. Note the small crankcase front section and the “archaic” cylinder heads. (They have different shape, and their fins are much shorter and widely spaced: these are indicators of a simpler casting technology). Another strange feature is the exhaust, which could be also mounted in the reversed (i.e. forward) direction. (Some of the aircraft from this era used front exhaust collectors). This engine used large spark plugs, mounted horizontally (in parallel to the centerline). It was rated at 575hp on takeoff, and used in some contemporary designs, like the Curtiss “Hawk” biplane.

Continue reading The R-1820 “Cyclone” Versions

Recreating the Wright R-1820 “Cyclone” (1)

The engine is the heart of every powered aircraft. In the case of the SBD it was the Wright R-1820 “Cyclone 9” (the “G“ model). In fact, this engine was one of the “workhorses” of the 1930s: designed in 1931, it was used in many aircraft, especially in the legendary DC-3. “Cyclone” was a reliable, fuel-saving unit for the Navy basic scout type. (Remember that the “Dauntless” was not only the bomber: it was also a scout airplane). In general, the R-1820 is a classic nine-cylinder, single-row radial engine (Figure 83‑1):

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Figure 83-1 The Wright R-1820 “Cyclone”, mounted on the SBD-5 airframe

The R-1820 G had been produced for over two decades, not only by the Curtiss-Wright, but also (under license) by Lycoming, Pratt & Whitney Canada, and Studebaker Corporation. Thus various less important details of this engine “evolved” during this period. In this post I would like to highlight some of these differences. I will focus on the forward part of this engine, because at this moment I am going to create a simpler model of the “Cyclone”, intended for the general, “outdoor” scenes. Inside the closed NACA cowling, you can see only its forward part. (Thanks to the air deflectors, placed between the cylinders – see Figure 83‑1). In such an arrangement, the visible elements are: the front section of the crankcase, cylinders, ignition harness, and the variable-pitch propeller governor. While the front section of the R-1820 crankcase remained practically unchanged in all versions, and the governor depends on the propeller model, I could focus on the cylinders and their ignition harness.

Identification of the version differences is the basic step, because otherwise you can build a model of non-existing object that incorporates features from different engine variants.

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Creating Textures: Color Map (2) – Weathering

In this post I will work on the weathering effects of the color texture, while in the next one I will add scratches and some other remaining details.

The weathering effects that you can observe on the aircraft from WWII era are quite “dramatic”. The paints used in mid-20th century were not as chemically “stable” as the contemporary coats, thus they could change their hues in few months of intense service. The archival color photos below show an extreme case of this effect (Figure 75‑1):

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Figure 75-1 Examples of heavy weathered aircraft

These photos were taken by Frank Sherschel on 14th November 1942, for the “Life” magazine. The SBD-3s depicted on the pictures belonged to VMSB-241 squadron, stationed at Midway in that time. Marines received these aircraft in July 1942, but all of them were already used before – most probably on the U.S. Navy carriers. I think that in November 1942 these SBDs had accumulated about 10-11 months of the war service. I will use them as an extreme case of the weathering. (It is always good idea to recreate such an ultimate case in the texture, because you can always make your model “newer” by decreasing intensities of the weathering layers. On the other hand, you cannot use more than the 100% of their intensities, thus you cannot make your model “older” than you initially painted).

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Mapping Images onto the 3D Model Surface (1)

Because of the holiday break, during July and August I will report my progress every two weeks. I will return to weekly reporting in September.

I have just begun the third stage of this project: “painting” the model. At this moment I am unwrapping its meshes in the UV space . I will deliver you a full post about this process next Sunday. Today I will just signalize how it looks like.

So I started by creating a new reference picture. It had to have a rectangular shape. Inside I placed my drawings of the fuselage, wings, and the tailplane (Figure 60‑1):

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Figure 60-1 Reference drawings for the UV map

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Fixing the Barrel Distortion of the Reference Photos

In this post I describe a break in the modeling that I made this week, because I had to fix my reference photos before the further work. The reason for this fixing was simple: the NACA cowling of my model did fit only the long-lens photos. For the further work I needed more information. This information was available in the high-resolution photos made by the Pacific Aviation Museum Pearl Harbor. However, they are slightly distorted.

In the ‘mathematically ideal perspective’ calculated for the computer cameras all of the straight lines remains straight. Unfortunately, the real-world camera lens can slightly deform (bend) the straight contours. This is so-called ‘barrel’ (or ‘cushion’) distortion of a photo. Unless you are using a panoramic lens, this deformation is hardly noticeable for the naked eye. Unfortunately, these differences become evident when you place a photo behind a 3D model, projected by a computer camera.

In case of reference photos that I used to verify my SBD Dauntless, the differences caused by the barrel distortion are visible around the forward part of the engine cowling (Figure 42‑1):

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Figure 42-1 The influence of the barrel distortion

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Modeling the Empennage (1)

The horizontal tailplane has similar structure to the wing — but it is simpler. Thus I started it in the same way as the wing, by forming its root airfoil (Figure 32‑1):

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Figure 32-1 Modeling the root airfoil of the horizontal tailplane

In the most of the aircraft the tailplane has a symmetric airfoil. So it was in the Dauntless. I did not find its signature (family) in any of the reference materials, thus I carefully copied its contour from the photos (its rear part — the elevator — seems to have modified shape, anyway). It has incidence angle of 2⁰, so I rotated the rib object and used a Mirror modifier to generate its bottom part.

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Verification of the Model Geometry: the Wing

In this post I will continue verification of my model by matching it against the photos. This time I will check the wing geometry.

In the first photo from the Pacific Aviation Museum (in my model it is marked as PAM-1) I identified several differences (Figure 31‑1):

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Figure 31-1 First differences that I found in the outer wing panel

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Verification of the Model Geometry: the Fuselage

In the previous post I introduced a new method of using photos. I fit the projection of my 3D model into the contours of the same airplane depicted on a high-resolution photograph. I can use such an arrangement as a precise reference. It is a good idea to verify the basic body of the fuselage in this way, when there are no additional details. All the differences that I will find now will save me a lot of troubles in the future. For example — what if I would find that the base of the cockpit canopy in my model should be somewhat wider, when this canopy was ready? I would have to fix both shapes: the canopy and the fuselage. And what if I would already recreate the inner fuselage structure — the longerons and bulkheads — before such a finding? I would also have to fix them all. This is a general rule: the later modifications require much more work than the earlier ones! Thus I have to check everything when the model is relatively simple. You can compare the differences I will find in this post with the plans I published earlier: they contain various minor errors! Just as every drawing.

Last week (see Figures 29-5, 28-7, 29-8) I discovered that the bottom contour of the tail was somewhat lower than in my model (Figure 30‑1):

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Figure 30-1 Verification of the fuselage side contour

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Matching the Model to the Photos

During the previous weeks I formed two main elements of my model: the wing and the main part of fuselage. As you saw, I could not resist myself for adding some details to the wing (like the ribs and spars of the flaps).

Now I think that this is a proper time to stop modeling for a moment and compare the shape of the newly modeled parts to the real airplane. If I find and fix an error in the fuselage shape now, it will save me from much more troubles in the future! If I find an error in the wing shape – well, I will have more work, because I already fit it with some details which will also require reworking… You will see.

The idea of using photos as a precise references emerged from the job that I did two years ago. One of my colleagues asked me if I can recreate the precise shape of the stencils painted on an airplane. He wanted to determine details of the numbers painted on the P-40s stationed in 1941 around Oahu. He sent me the photo. I started by fitting the 3D model to this historical picture, finding by trial-and-error the location and focus of the camera (as in Figure 29‑1):

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Figure 29-1 Using an photo to precisely recreate stencils and roundels of an historical P-40B

Then I made the model surface completely transparent. I placed the opaque drawing (texture) of the large white tactical numbers on its fuselage, and the black, smaller, radio call numbers on the fin. I rendered the result over the underlying photo, finding all the differences. Then I adjusted the drawing and made another check. After several approximations I recreated precisely shapes and sizes of these “decals”.

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