Wessex lovers?

[blue up]

I'm starting to embark on a Museum rebuild of an ex-RN Wessex. Are there any Ppruners who I could call upon for photos, manuals and occasional e-mailed maintenance tips?

The rotor head and the engines are coming from another airframe in terrible condition and I'm certain there are parts missing. Any help would be gratefully received, especially if you happen to live near St Athan and have time on your hands. I could buy you a bacon butty in the cafe. I'm alright doing the skin work but will need help getting the oily bits in the right place.

Thanks

Rob
https://cimg5.ibsrv.net/gimg/pprune.org-vbulletin/980x735/wesx1_f595e7197678b72c40ae88cc5049064490db76f3.jpg
https://cimg6.ibsrv.net/gimg/pprune.org-vbulletin/647x328/wesx5_ed7e21793edf02d44f5c288f2a890a8ffdfeb54d.jpg

[Bravo73]

Good luck with your endeavour.

Have you discovered this thread yet? https://www.pprune.org/rotorheads/123915-what-about-wessex-makes-people-so-fond.html If you haven't, I suggest that you make a brew and start at post 1. You might even find your airframe mentioned in the thread already.

[nomorehelosforme]

Good luck with your endeavour.

Have you discovered this thread yet? https://www.pprune.org/rotorheads/123915-what-about-wessex-makes-people-so-fond.html If you haven't, I suggest that you make a brew and start at post 1. You might even find your airframe mentioned in the thread already.

That thread should be retitled 'The Wessex Bible"

Blue up would be great if you kept this thread updated with progress, good luck!

[blue up]

https://cimg0.ibsrv.net/gimg/pprune.org-vbulletin/998x739/wesx8_fc5c33c9783d3dc40df8656bada5872728e583cc.jpg


We have another 'spares' ship here but it is a little.....crusty.

[blue up]

A quick question?...The tail release ratcheting system has failed so that although the handle releases there is no movement of the locking/unlocking mechanism, kinda like a Chinese socket set.:* Any photos or diagrams of how the mechanism works?
Thanks.

[[email protected]]

It extends the pins up and down into the brackets.

[NutLoose]

I have some walk rounds I have done,

https://www.flickr.com/photos/142550108@N08/albums/72157677179160002

its so long since I worked on them, when you pull the handle out if I remember correctly you rotate it so the pin points in the direction of travel then ratchet it.



..

[MENELAUS]

That’s also a 737 cab. Even more complicated than the V. What’s the inside like ?
And have you got the single engine Mamba in there ?

[Democritus]

That’s also a 737 cab. Even more complicated than the V. What’s the inside like ?
And have you got the single engine Mamba in there ?
Mamba? - in a Gannet maybe but it was a Napier Gazelle in the Wessex HAS Mk3. My old eyes can't make out the reg - XM833? If so missed it by one, the nearest one I flew was XM834!

[MENELAUS]

Yep apologies. Double engine mamba was indeed the preserve of the Gannet.
I had it in mind that the Wx III had a single engine v. of it, not the Napier Gazelle.

[Dave B]

Get hold of a copy of the Haynes "Owners Workshop Manual".for the Wessex By Lee Howard, ISBN 978 1 78521 117 1. Lots of pictures, drawings and stories.

[blue up]

2 rotor heads and 2 engines, one of them still new in the box.:)

I think I now know how the ratchet mechanism works. That handle with the pin in it won't rotate, only unclip from the holder. Very rotten, too. I might have to salvage bits from the rot-box. Same as the S61/SeaKing?

Haynes manual is on order!

Ta.

[peterperfect]

Mamba? - in a Gannet maybe but it was a Napier Gazelle in the Wessex HAS Mk3. My old eyes can't make out the reg - XM833? If so missed it by one, the nearest one I flew was XM834!

XM833 left 737s books in 1981. By the look of the more faded paint aft of the Tx joint, is it all XM833 or just the rear half ??

[Tashengurt]

https://cimg0.ibsrv.net/gimg/pprune.org-vbulletin/998x739/wesx8_fc5c33c9783d3dc40df8656bada5872728e583cc.jpg


We have another 'spares' ship here but it is a little.....crusty.

Has that come from Sunderland?

[blue up]

I think it is the one we dragged out of the Fire College at Moreton-in-the-Marsh. XP150??

[NutLoose]

If money wasn’t a restriction there is a new tail on evil bay.

https://www.ebay.co.uk/itm/WESTLAND-WESSEX-HELICOPTER-TAIL-BOOM/163644624223?hash=item2619facd5f:g:9QUAAOSwHLNZU80Q

[blue up]

Ah, too expensive, I'm told.:{

Meanwhile...
https://cimg2.ibsrv.net/gimg/pprune.org-vbulletin/980x735/img_1045_6d5e4b877d0d21f0e4618cb7c52766222adccb51.jpg
next bit made today.

Went to look at the instrument panel in storage. Some little ****** has smashed every single bit of glass in it.

[blue up]

https://cimg5.ibsrv.net/gimg/pprune.org-vbulletin/988x741/wesx9b_d575077fc38bac9529664d10d4b32c6a422ef7d8.png
Slight corrosion. Isopon or Duct Tape?

[Self loading bear]

Remember to sand it rough so the adhesive will stick better.

[NutLoose]

Still four full screw holes, its a go'er to use it, think of the weight saving advantages.... BTW nice to see some good tin bashing going on.

BTW price has dropped..

https://www.ebay.co.uk/itm/WESTLAND-WESSEX-HELICOPTER-TAIL-BOOM/163644624223?hash=item2619facd5f:g:9QUAAOSwHLNZU80Q

[sycamore]

Thought it was another slice of Swiss cheese..

[Georg1na]

I am really enjoying this "restoration" - brilliant work! Yeee Haaaa!!
https://cimg6.ibsrv.net/gimg/pprune.org-vbulletin/1920x2000/140_degrees_bank_09f9d0bd5581384477a798570253a566135e1f80.jp g

[Fareastdriver]

The clouds looks better the right way up.

https://cimg5.ibsrv.net/gimg/pprune.org-vbulletin/1911x2000/140_degrees_bank_09f9d0bd5581384477a798570253a566135e1f80_45 1c26a697323f1ccdd788d80082e586c72d56f1.jpg

[Georg1na]

Clearly never flown the Wessex then! 140 degrees of bank quite usual entering dispersal!:E

[Bergerie1]

Oh dear!! And I thought this was a novel by Thomas Hardy.

[[email protected]]

Georg1na - :ok: wingover to land sir? Suits you sir, suits you:)

[Georg1na]

Got me into trouble at Valley on one occasion..............:eek:

[sycamore]

G, 22 Sdn roof...?

[Georg1na]

Well there was also a piano at Valley that played a bum note - the ensuing blaze stopped night flying as the fire tenders were all at the mess. 11 Squadron Lightnings were deemed to be at fault but we stepped in with the enclosed to hep!Is there still an 11 Squadron and do they still have the trophy?

https://cimg6.ibsrv.net/gimg/pprune.org-vbulletin/1360x2000/navy_photos_80__2b8f1e6bbfb48e91b336cf6abd90d7bc82abf4b4.jpg

[blue up]

Has anyone hereabouts ever seen a Wessex rotorhead being removed? The front mounts seem to be in such a position that they foul the rear of the Penthouse Suite. Ours has some nasty damage to the vertical section just aft of the seats, presumably from someone removing said rotorhead with an axe or similar. Does the roof/windscreen come away for this job or is there some secret way to get it all to fit?

Thanks,

Confused, of Cardiff,

[sycamore]

There is a big nut at the top of the rotorhead marked `Jeezus`...unscrew,disconnect pitch arms,lift off...
You seem to be trying to lift GBox...Have you tried reading the manual...?

[Cornish Jack]

G, 22 Sdn roof...?
Memories, memories!!! :eek: :=

[Dave B]

You need a special tool kit called a Hydrapack ram for undoing the top nut. As someone has said, you seem to be trying to remove the head and gearbox together. Is there not an old Wessex man around your parts, head removal is straight forward.
The Wessex schedule used to be a pain, because the head and gearbox O/H lifes were not the same so you would have to remove the head at 800 hours to change the gearbox, put it back on, and then remove it again at 1000 hours.

[blue up]

Sadly, no manuals, other than the Haynes manual which is on back order. We could maybe lift the rotor and gearbox in one piece but it looks from the ground as if the legs of the gearbox are wider than the hole in the upper frame that it has to pass through, hence the damage just above the front mount. I'll try to get a photo of the butchery later this week.

10K hours on fixed wing but no rotary time so it is all a bit new to me. I'm more into wooden airframes and vintage cars.

[Dave B]

If you want to remove the gearbox after the head is off, you have to allow for the mast forward tilt. Deflate the rear oleo, pump up the front oleos and get as much nose up as you can. You then need to use a crane with the correct gearbox lifting tool, and with a couple of the biggest blokes you can find, lift the back of the box to clear the canopy.

[blue up]

https://cimg8.ibsrv.net/gimg/pprune.org-vbulletin/745x686/wesx11_4ee66116d913f069c71524f383eaefb1f883af09.png

Someone chopped the vertical section of the cabin to get the frame out. Not going to be fun to replace. It does look as though the area has been repaired before, suggesting this isn't an unusual area to have to repair.

[Dave B]

blue up
If you are still intending to remove the major components, I would suggest you must get the correct tools, slings, and stands to mount the bits on. With the amount of Wessex in service with the RAF, Navy, and Bristow, I would think that there must be some surplus gear around some where, unless its all be scrapped.
The Wessex is not a light aircraft, and these components are heavy, and will cause injury if mishandled, and I would suggest you need at least one person who knows what they are doing.
The head sling is a light cable assembly, with a loop for a shackle, its will not take the weight of the head and gearbox in one .The gearbox is slung from the mast, with a screw on fitment, and an eyelet.
I have no wish to put a damper on your project, but health and safety will not be impressed if you use the wrong gear, and I am sure you value having all your limbs intact.

[sycamore]

Blue,speak to the guys in Chard at least,or the Museum director at W-S-M...

[blue up]

Manuals arrived this morning from DG93. Many thanks for your kind and generous offer! :ok:

I don't know who will be doing the heavy lifting but I'm hoping to get everything arranged in advance so that their task will be easier. Metalwork is my preferred area. By the sounds of it I should delay fixing the damaged rear of the cockpit until after the twirly bits are installed. Thanks.

http://www.hmfriends.org.uk/restorwesx3pge3.htm Looks like I need to make a visit.

[sycamore]

b-u ..,as an old one time rigger/tinbasher,I think you might `consider` doing the bashing when the head/g-box are off,and the top deck is cleared.... as the area at the back of the `cockpit is `busy` with control rods,pipes,etc
as it`s been bashed/slashed,it needs `rigging `properly,otherwise the panels may not fit.........only a suggestion,DaveB might concur....or not!

[Dave B]

Sycamore
My only worry was that someone not using the right gear, and not being familiar with the job, may get hurt. As an ex Wessex chief engineer, I must have done many gearboxes, but the potential for losing fingers is always there.
The 3deg mast tilt means you cannot get a straight lift on the mast, you have to tilt the aircraft at an extreme angle. The S76 is the same, but with a 5deg tilt.

[NutLoose]

When you take the gearbox off wasn’t there a couple of cables you had to add to prevent the canopy sagging fwd.

[Dave B]

Not to my knowledge NutLoose, but I never worked on any of the Navy versions, perhaps they had extra gear. Anyone who has read Richard Pikes book helicopter boys, will have read about the Bristow crash in Indonesia. This was an ex Brunei army Mk. 50, and it was jinxed. We spent Two years rebuilding it at Redhill, after which it went to Port Harcourt in Nigeria, after a year or so of good service it turned over due to ground resonance. It was repaired again on site, only to be finally lost after I left due to a tail servo malfunction. As for as I know its still there in he swamp.
Barney Swinton-Bland was flying a Whirlwind in PH, when he had a blade pocket lift, we rescued him as he floated merrily down the river on his pontoons. We dumped the blade, and the next time we flew over we saw that the locals had retrieve it, mounted it no tressles and were using it to cut up fish on. Who say Shell dont care for the environment.

[sycamore]

Black `bodge-tape`(long before`speed-tape) was the answer to lifted pockets on WW.....until you flew thru` the next tropical rain shower.....or until the `Glovers` sorted the problem...eventually...

[Georg1na]

Do you remember the silver metallic tape that was stuck along the leading edges of Wessex V blades in the Far East to reduce erosion from heavy rain? All that happened was that the rain split the tape and your leading edge had all the aerodynamics of a house brick! And with all the attendant vibration................Happy days

[Fareastdriver]

I'm with sycamore. We always used black tape on our Whirlwinds in Borneo.

[[email protected]]

We had clear blade tape in NI in the 80's which often lifted in heavy rain causing the classic 'Wop, Wop' sound.

The tape usually removed itself if you kept flying but on one occasion it didn't and we landed and shut down to discover that one of the blade pockets had removed itself instead!

[Fareastdriver]

In Borneo we found that the standard Smith & Wesson .38 and 12 rounds we were issued with was useless. Shooting against a headwind you could see the bullet and if it got more than twenty yards the bullet was so far off target that you victim was fireproof.

You could tear the old black blade tape into very thin strips. One would then wrap them into the groove on the 9 mm cartridge. The enabled you to place them in the chamber of a .38 Smith & Wesson and the tape would act like the rim on the pistol's cartridge.

The difference was fantastic and with the bigger charge six shots into a fuel drum at 50 yards was easy. The only problem was that you had to poke the empty shells out with a screwdriver as the extractor would not grip the tape..

!2 rounds of II WW ammunition or unlimited 9 mm from the Ghurkas? No contest.

[zetec2]

Couple of Wessex with head sling in place, although shouldn't really lift the head with blades attached if I remember correctly ?.
https://cimg1.ibsrv.net/gimg/pprune.org-vbulletin/1460x2000/image_12__f5e00cf941ed8ea708d4bd18af320d5d40897c9b.jpg

[Fareastdriver]

Looks as if it has just been put on a cradle for transport.

[sycamore]

z2, think that might have been a `staff` navigators `landing`...!

[zetec2]

slight bend in rear fuselage through the serial, on a transporter back at Finningley about September 82.
https://cimg3.ibsrv.net/gimg/pprune.org-vbulletin/1460x2000/image_8__172320afdcd5145b16f2d372c6aa571b062375d1.jpg

[sycamore]

Z2, think it was at Coltishall it happened.....

[racingrigger]

The sling" shown in the photo is not strictly a head sling but a sling capable of lifting the head and gearbox as a complete unit. It is of all metal construction (probably mild steel) and can be used to lift not only the head and gearbox unit but the compete aircraft! The head (only) sling is a four legged wire rope sling affair of altogether more flimsy construction.

With regard to the query about cockpit wire rope cables, they should be fitted to support the cockpit rear bulkhead when the longerons either side of the main gearbox are to be removed prior to lifting the gearbox. They fit between the lower forward corner of the sliding window rail and the top rear corner of the sloping bulkhead.

Incidentally the aircraft does not have to be tilted to remove/refit a main gearbox. A couple of strong guys pulling rearwards on the gearbox A frames as the gearbox is lifted/lowered will allow the front A frame legs to "clear" the base of the cockpit bulkhead.

[Dave B]

https://cimg9.ibsrv.net/gimg/pprune.org-vbulletin/1584x1036/heli_120001_small_0b1150f7a49e451bb9a02aec2ba16d9169963376.j pg
Hill top Jambo 1965
Far East Driver, does this bring back any memories.

[sycamore]

Gotta date Dave...? 225 Sdn `D`,until Nov`65 then 103 Sdn....

[Dave B]

Sorry Sycamore I was never very good at keeping diaries, but this would have been Summer 1965, after the New Zealand Regiment took over the area, from the Gurkhas, I was in charge of maintenance at Simanggang. Your right about it being 225, and shortly before Sam Smiths accident, operating from Kuching.

[sycamore]

Don`t know if you were on this ..? Your Eng.O is 2nd left ,seated...possibly Oct`65

[NutLoose]

With regard to the query about cockpit wire rope cables, they should be fitted to support the cockpit rear bulkhead when the longerons either side of the main gearbox are to be removed prior to lifting the gearbox. They fit between the lower forward corner of the sliding window rail and the top rear corner of the sloping bulkhead.



Thanks, glad I’m not going mad and remember them even as a sooty, I even remember on the HC2 you need to put the v strut back in before removing the second engine, I saw one that they didn’t and the nose sagged, it was fixed by putting an aircraft jack on the angled eng bay decking and jacking it back up to slot one back in. :)

[Fareastdriver]

Far East Driver, does this bring back any memories.

Not really. I was up north in Sabah, well away from the fleshpots of Kuching. XP330 was handed over to us when we left Labuan and it then served on 230 Sqn.

[NutLoose]

This might help in your rebuild


https://www.ebay.co.uk/itm/RAF-RN-Air-Publication-AP101C-0102-010-0105-6B-Wessex-HC-Mk2-HCC-Mk4-HU-Mk5/184549369607?hash=item2af7ffe707:g:I7gAAOSwp6xfu8cZ

[peterperfect]

This might help in your rebuild


https://www.ebay.co.uk/itm/RAF-RN-Air-Publication-AP101C-0102-010-0105-6B-Wessex-HC-Mk2-HCC-Mk4-HU-Mk5/184549369607?hash=item2af7ffe707:g:I7gAAOSwp6xfu8cZ

I bet it still smells of OX 38 !

[ericferret]

I bet it still smells of OX 38 !


I still smell of OX 38

[NutLoose]

Lol, me too

[spitfirek5054]

I preferred OM 15

[spitfirek5054]

I was at RAF Kai Tak, when the pylon fell off when it was being folded.

[ericferret]

I preferred OM 15

On a scale of nastiness I always rated OM15 as worst with Avtur next.
Mind you at that point I had not discovered Skydrol, gods punishment for taking up aircraft enginering.

[NutLoose]

Skydrol and VC 10, used to leak all over you when doing pump changes on the engines, nasty paintstriping stuff.

[sycamore]

Spit..,was that due to corrosion,or incompetence ,or..other...?

[spitfirek5054]

A crack had developed in the Upper Hinge,as far as I remember,there was no inspection done there, had to get MARTSU out to repair it.

[sycamore]

Spit...thanks

[spitfirek5054]

They brought a Mod. out to replace the single upper hinge with a double hinge, apparently the crack developed from the inside.
We had to do NDT every 5 flying hours,later extended to 10, Eddy Current was the preferred test,but if not available Ardrox.

[3D CAM]

Quote "On a scale of nastiness I always rated OM15 as worst"
OM15 = instant Dermatitis. Awful stuff. I never had any reaction at all to Fluid 41...hmmm
3D CAM.

[huge72]

As a Crewman, I used to wear OX38 all down my back. Straight off Top Deck down bulkhead and onto me. You could always tell the difference between pilots jackets and crewman's, forget badges just see who smelt of the stuff!

[Dave B]

Anybody who worked on Hunters, single engine Wessex, or Belvederes will be familiar with Avpin. We had a guy on Belvederes who swallowed some, on that aircraft the Avpin tank was up high on the side of the cabin, you had to stand on a hook on ladder, and pour the stuff in from a plastic can.
This guy fell back off the ladder, and Covered himself in Avpin, the sick bay kept him in, and checked his blood pressure every few minutes, but he was OK.

[Fareastdriver]

It was lucky he didn't fart.

[WASALOADIE]

Huge 72, I used to joke that I took my flying suits home for an oil change. Hope all is well, Happy Christmas my friend :) AP

[NutLoose]

you got the avionics... well.... fuses and big clunky electrical components bay door would be a better description...

https://www.ebay.co.uk/itm/Westland-Wessex-panel-aircraft-part-engine-cover-right-side/233887987246?hash=item3674cf762e:g:UNoAAOSwk6RfHaz9

[mole man]

I still have my flying jacket and stain on shoulder (still smells of oil) and I left 72 in 1980

[nomorehelosforme]

Blue Up,

Any updates/pictures on the project?

[Boslandew]

I did a tour in Aldergrove in 1971 with the Air Corps flying Scouts. We shared a hangar with the Wessex squadron. There was a rumour that an American pilot on exchange with the RAF used to demonstrate engine-off landings in the Wessex without touching the collective, just a massive flair and lots of judgement. Any truth in that rumour?

[ShyTorque]

He’d need to have a lot of personal “flair” to do it all using just the “flare”, but not impossible, I’m sure.

[Nigel Osborn]

Our squadron QHI in 848 used to do EOL just using the cyclic in the Wessex 5. However it was not standard practice for us plebs!

[Georg1na]

Nigel - did I not teach you that one?

[Nigel Osborn]

I don't know your real name but message me if you wish! I had it demonstrated but only did 2 as that was enough! In Malaya come to think of it!

[N707ZS]

Going back to Oct 20 in this thread, XP330 lingers at Teesside airport. Sorry for the Whirlwind content.

http://www.dtvmovements.co.uk/images/Residents_Current/Serco_IFTC/XP330_SR.jpg

[Dave B]

Sad picture, but I guess we all end up like that. The powers that be were never sentimental about aircraft, I speak as one who worked on the last Two Beaufighters in service. At the end these Two still flying aircraft were broken up by Chinese contractors using an axe.