Jerry Small Estrelitta F1

[kane]

Last year we had the opportunity to purchase an Estrelitta fuselage. The kit didn't have any wings or tail components. There are no molds available for this model and I took the opportunity to turn the fuselage into a plug and make a mold. Ultimately with the plan to build and fly this beautiful airplane at the 100 yr NATs celebration. I will document the process through photos in a series of posts.

Throughout the process my buddy Jim DeYoung provided tons of support and help. Jim, made the mold after I finished the plug and splitter. He also cut the foam wing cores.

[kane]

The next series of pictures shows how I made the master for the clear canopy. When we received the kit it included a Kaze Killer canopy and was not the correct shape for the Estrelitta. So... I made a mold and sent it off to Keith Sparks and he made a master for clear canopies!

Also shown here is the foam wing cores with a spar and sheeting.

[kane]

Tail feathers were designed as well as the wing TE and Tips. And the shaping/sanding has begun.

Wing halves are joined, hardpoints installed and wing is mounted.

[kane]

Cockpit floor and pipe trough plugs are finalized. Gear is potted and the glassing process has begun.

[kane]

Molds are built and parts are made for the cockpit floor and pipe trough. Glassing continues.

[kane]

Wing and gear potted. Firewall installed, cowl fitted and pipe trough installed. Tail feathers installed and pilot painted.

[kane]

Canopy fitted, hinges installed and final assembly.

[kane]

Primer and Paint

[Jim DeYoung]

Danny,
The Estrelitta is a beautiful airplane. You did a fantastic job of building it!
Jim

[fizzwater2]

Dan - superb craftsmanship! The plane looks great!

[dwc1]

The pictures don't do it justice. It is a beautiful airplane.