some assembly required dave grant
TRANSCRIPT
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The C-141 StarLifter
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This is some of the tooling used
to manufacture the C-141.
These were used to shape the
sides of the fuselage.
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In this picture you can see
the aluminum skin being
applied to the segment.
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The completed segment is moved
to a holding area, until needed.
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In the lower foreground, is thelower bulkhead that the upper
aft fuselage will be built upon.
The section on the left side of
the photo is being moved to
mount on the bulkhead.
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The upper skin segment of the aft
fuselage is being attached to the
lower bulkhead. The hole in the top
will be inside the vertical stabilizer.This is one of several stations
assembling this segment. All the
segments are being manufactured
concurrently, and will be joined at
the final assembly.
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This is the aft segment of the
aft fuselage, which will be
moved and joined with the
bulkhead, and forward section.
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Aft segment being mated with the
bulkhead and forward section.
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The aft fuselage upper segment, now
completed, is being mated with the fuselage
side segments in an alignment fixture.
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The upper cap for the aft fuselage is
being installed. The number three
emergency escape hatch is visiblein the forward section of the cap.
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Upper forward fuselage framework.
The aluminum skin is being attachedon the left side of the picture.
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Upper forward fuselage with
the aluminum skin attached.
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Lower forward fuselage beingassembled in fixture. It is assembled
upside down for ease of assembly.
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Lower forward fuselage being
moved to mating fixture. The
section on the right side with the
two holes is the forward bulkhead
where the radome will attach.
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The lower forward fuselagesection is in place in the
alignment fixture as the
upper section is lowered into
position for mating.
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The completed forward fuselage
segment is completed and moved to
the fuselage mating jig. As you can
see this is the first C-141A StarLifter.
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Fuselage Station 1058 main frame. This is one of four main frames that
completely encircle the fuselage. Main frames are located at the front and back
of the center wing, they support the airplane while airborne. Fuselage station
998 and 1058 main frames support the airplane while it is on its wheels.
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A section of the center
fuselage that contains, frombottom to top, the 1058, 998,
and 958 main frames.
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Center fuselage floor segment being
lowered into an alignment/mating fixture.
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Center fuselage main frame
segment being positioned
near alignment/mating fixture.
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Main frame segment
being mated with floor
segment. In the lower
center of the pictureyou see a large hole
where the crane cable
is attached. This will
be used to hold the
main landing gear pivot
pin. It is located in theFS998 main frame.
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Floor panels are installed in the
center fuselage. In addition to
acting as a floor, the panels
provide stability to the structure.If the floor panels were not
installed the segment could
become distorted cause failure.
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Main frame segment being
lowered into alignment and
mating fixture.
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Lower section of the center wing box being
installed in an alignment fixture. You can see
the upper pressure diaphragm that will becontained within the assembly.
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Lower center wing placed in the alignment
fixture. Notice the risers on the sides of
the panels. These were milled to shape in
order to provide strength to the panels.
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In order to save space on the
manufacturing floor, the upper
surface of the center wing wasassembled vertically
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The upper surface of the center wing box
is being lowered on top of the lower
surface in the alignment/mating fixture.
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Center wing box being moved to centerfuselage alignment/mating fixture. The
dark square hole is to provide access
for maintenance personnel.
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Lowering the center wing box
into the fixture.
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Fuselage mating fixture. All three segments of the
fuselage will be aligned and mated in this fixture.
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Center fuselage section from fuselage
station 734 through station 1058. It is
being moved toward the mating fixture.
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Center fuselage being placed into the
alignment/mating fixture. The center
fuselage is the heart of the airplane. All
other assemblies will be aligned to it.
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Aft fuselage being lowered onto the
alignment/mating fixture. Once on thefixture it will be moved forward to mate
with the center fuselage.
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Main landing gear pods. They do not
carry structural load, and their only
purpose is to provide an aerodynamic
enclosure for the landing gear.
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Main landing gear pod installed on the left
side of the airplane.
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Main landing gear strut
ready for build-up
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Adding the brake, wheel,
and tire assemblies. The
tires are 28 ply 44 x 16
inch radials.
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This is the brake assembly. It is a multiple
disc assembly. Just behind the brake is the
bogie beam positioner which keeps thewheels level for landing.
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Measure with a micrometer, mark it with chalk, cut it with an ax.
The landing gear doors are installed and trimmed to fit with the
landing gear retracted into the wheel well.
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The complete fuselage supported by its own wheels.
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The wings were made off site, and
brought to Marietta, GA by train.
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The wings are brought into the facility, and
prepared for assembly. They are only a fuelcell at this point. The trailing edge and
leading edge components will now be added.
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The facility was also being used forproduction of other airplanes at this time.
The C-140 (JetStar) in the background
was in the final production area. Later in
the production of the C-141A, the C-5A
production line was started.
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The trailing edges are
being installed. Thisincludes the flap tracks.
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Once the trailing edge is attached to the wing,
preparations are made for wing installation.
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The wing is in transit. If you notice the
crane operator is in the little bucket up
near the ceiling. At that time, the crane
operator rode up there, now he walks
on the floor with a long lead control box.
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Right wing is lowered into position,
and will be aligned and mated tothe fuselage. Four tension bolts
and chordwise splice joints hold the
wing to the fuselage.
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Bringing the left wing into
position for installation.
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The fuselage now has wings. Next will be
the ailerons, engines and all the plumbing
and wiring for the wings and engines.
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The ailerons are swung into position
and installed.
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The engines are hung,
and the necessary wiringconnected and routed
back to the fuselage.
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Engine cowl door will be placed on the engine once the
engine is completely installed on the pylon.
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Engine installed with cowl
doors open. You can see the
wiring, fuel and hydraulic
lines running up the leadingedge of the pylon.
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The fuselage, wings, and
engines are installed, now
its time to work on the tail.
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Petal door being brought intoposition for installation. The cutout
on the left end was where the
auxiliary petal door was located.
The first few models had this
feature for the paratroopers to jump
out. Unfortunately, they wouldbump their heads, so the door was
eliminated, and they jump out the
side doors now, or the back with
the petal doors open to the air drop
position.
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The petal doors are
installed. As you can see
inside the fuselage there is
still a lot of work being done.
The pressure door will be
installed next.
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Horizontal stabilizer. Actually this is a test assembly
used to ensure the T-tail could be attached to the
airplane while inside the building.
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Vertical stabilizer. The
horizontal stabilizer will be
attached to the top of thisassembly in the fixture on
the right side of this picture.
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Fully assembled horizontal stabilizer
being moved into position for mating tovertical stabilizer.
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Once mated, the T-tail will
be moved to the fuselage
and installed as an
assembly.
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During the mating process, thenose of the airplane was jacked
approximately five feet off the
ground to allow the crane operator
to position the T-tail. Once
attached, the airplane could sit
normally on its wheels withadequate clearance for the T-tail.
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Before we get too far, we need to take the
plane over to the paint barn and get allthe correct markings and insignias.
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Back from the paint barn, we have all themarkings. Final flight control rigging, and
other cosmetic operations are being
completed in preparation for roll out.
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August 22, 1963 the first C-141 airplane AF61-2775
rolled out of the Marietta, GA facility
The C-141 on display with
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The C 141 on display with
a C-130 and C-47.
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First flight of the C-141 took place on December 17, 1963. The
sixtieth anniversary of the Wright brothers first flight.
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The 285th C-141 built was made as acommercial demonstrator (designated
the L300). It was acquired by NASA in
March 1971, and modified to carry an
airborne telescope.
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In December 1975, the C-141Awas brought to Marietta, GA for
stretch modification prototype.
This modification added 23 feet
to the length of the airplane.
271 airplanes were modified.
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In February 1979, the first
MAC C-141s arrived formodification. At peak
production, a rate of 10
airplanes per month were
being modified.
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July 18, 1979 the first stretched C-141 rolled out of the B1
manufacturing facility. The first operational C-141B was
assigned to Travis AFB, CA on April 11, 1980
Some were equipped for
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Some were equipped for
special missions.
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In 1997, the automatic flight controlsystem and flight instruments were
upgraded to the glass cockpit. This
created the C-141C model.
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