Stinson L-5 Sentinel 42-98774
'June'
Restoration Page 1
1942 Stinson L-5 VW Sentinel 42-98774 as purchased in North Carolina in August 2018
I would like to thank the following people and businesses for their technical assistance and services:
Gene and Kay Vaughan - Former owners
Mike Horn - IA - Technical knowledge, supervision, tools and work space
Paul Philipps - Electrical technical knowledge and cannon plug wiring
James Gray - President, Sentinel Owners and Pilots Association - History and technical knowledge
Sam Tabor - Tab-Air - Technical knowledge and parts
Duncan Cameron - Owner of several L-5s - Technical knowledge and parts
Mike Amble - Amblin Antique Air Inc. - Engine overhaul
Ester Aube - Air Corps Aviation Library - L-5 manuals and Stinson Factory Drawings
Travis Millhouse - Provided original Army - Navy Air Craft Camouflage Standard Color Cards dated June 1943 for color matching
Joshua DeJong - The Rigger Depot - Custom built reproduction 1941 S-2 Seat Type Parachute, First Aid Kits and Headphone Cups for display
Air-Tech Coatings - Fabric and primers
Alliance Coatings - Paint
Keystone Instruments Inc. - Instrument overhaul
Sensenich Wood Propeller Co. - New wooden propeller
Pacific Oil Cooler Services - Oil cooler overhaul
Zeftronics - Generator Control Unit
Grove Aircraft - Wheels and brakes
Airwolf Filter Corp - Oil filter
References:
- TCDS Aircraft Specification No. A-764 06 Sep 1949
- Stinson Factory Drawings 76- Series published in Air Corps Aviation Library Online
- T.O. 01-50DB-1 – Flight Handbook – L5, OY-1, OY-2 15 Jul 1953
- T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- T.O. 01-50DB-3 – Structural Repair Instructions – L-5 02 May 1949
- T.O. 01-50DB-4 – Illustrated Parts Breakdown – L-5, OY-1, OY-2 15 Apr 1956
- T.O. 01-50DB-5 – Basic Weight Check List and Loading Data – L5, OY-1 30 Jun 1950
- T.O. 01-50DB-6 – Inspection Requirements – L5, OY-1, OY-2 15 Dec 1955
- T.O. 01-50DB-13 – Modification of Carburetor Hot-Air Intake System for L-5 26 Mar 1944
- T.O. 01-50DB-17 – Replacement of Muff to Carburetor Tube Assembly for L-5 14 Aug 1944
- T.O. 01-50BD-18 – Replacement of Fixed Pitch Wood Propellers for L-5 06 Jan 1945
- T.O. 01-50DB-20 – Reinforcement of Pilots Safety Belt Installation For L-5 18 May 1945
- AN 02-15BA-2 Service Instructions – O-435-1 10 Nov 1944
- AN 02-15BA-3 – Overhaul Instructions For O-435-1 Aircraft Engines 10 Apr 1945
- AN 02-15BA-4 Parts Catalog O-435 Engine 04 Aug 1948
- AAF Manual No. 00-20A-2-L-5
- AAF Manual No. 50-18
- AD 47-50-04
- AD 46-31-02
- Lycoming Overhaul Manual Model O-435 Engine
- Lycoming Service Instruction No. 1427C Lycoming Reciprocating Engine Brake-In and Oil Consumption dtd 29 Dec 2010
- AC 43.13-1B Change 1
- AC 43.13-2B
- Air Tech Coatings Fabric Covering Procedure Manual AT 101 Revision 8
NOTE: Information provided in this build log is for educatiional purposes only and does not constitute a complete list of all tasks performed and all references utilized.
DATE: 08 – 25 OCT 2020
- (P) Removed propeller IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (E) Removed engine and accessories IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Removed cowling, ailerons, flaps, wings, rudder, tail cone, trim tab, elevator, horizontal stabilizer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Removal of the Lycoming O-435-1
DATE: 26 OCT – 21 NOV 2020
- (A) Left Wing – Removed fabric, disassembled, cleaned, inspected, removed parts, removed old hardware removed all wiring, and performed minor repairs. No Casein glue noted IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Left Wing Fuel Tank – Cleaned, inspected, tested, and primed tank with Air Tech Coatings Epoxy Metal Primer. Resealed and installed fuel gauge IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Left Wing – Cleaned, inspected and primed all metal parts with Air Tech Coatings Epoxy Metal Primer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Left Wing – Varnished all wood with two coats Air-Tech Coatings Spar Varnish IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Left Wing - Installed new wiring, installed parts with new hardware, installed fuel tank, replaced all felt pads for push-pull rods IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Johnson Furniture Company in Grand Rapids, MI built the wings for Stinson shown above is their inspection stamp. Also note the word 'Haskelite' and diamond stamp, Haskelite was a company in Michigan that made plywood
After removing fabric from left wing, the above signature was found "Love Jenine". Female factory workers are known to have worked in the Stinson factory performing fabric covering, welding, sheet metal fabrication and assembly.
Two coats of epoxy varnish applied to seal the wood
The L-5 has two 18 US Gallon fuel tanks, one in each wing
After being sealed with varnish, new wiring is installed for landing light and position light. Pitot static tubing installed. Push-pull rods for ailerons installed. Flap controls installed
DATE: 22 – 28 NOV 2020
- (A) Left Wing – Covered with Ceconite 101 that meets TSO C-15d dtd February 26 1990, rib stitched, taped and primed wing IAW Air-Tech Coatings STC# SA7965SW, Stinson Factory Drawings 76- Series, T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956 and AC 43.13-1B Chapter 2 Sections 1-4
Wing is primed with an Air-Tech epoxy primer that seals the fabric and provides UV protection.
DATE: 28 NOV – 20 DEC 2020
- (A) Right Wing – Removed fabric, disassembled, cleaned, inspected, removed parts, removed old hardware removed all wiring, and performed minor repairs. No Casein glue noted IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Right Wing Fuel Tank – Cleaned, inspected, tested, and primed tank with Air Tech Coatings Epoxy Metal Primer. Resealed and installed fuel gauge IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Right Wing – Cleaned, inspected and primed all metal parts with Air Tech Coatings Epoxy Metal Primer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Right Wing – Varnished all wood with two coats Air-Tech Coatings Spar Varnish IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Right Wing - Installed new wiring, installed parts with new hardware, installed fuel tank, replaced all felt pads for push-pull rods IAW T.O. 01-50DB-2– Maintenance Instructions – L-5, OY-1 15 Apr 1956
DATE: 21 – 25 DEC 2020
- (A) Right Wing – Covered with Ceconite 101 that meets TSO C-15d dtd February 26 1990, rib stitched, taped and primed wing IAW Air-Tech Coatings STC# SA7965SW, Stinson Factory Drawings 76- Series, T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956 and AC 43.13-1B Chapter 2 Sections 1-4
DATE: 26 DEC 2020 – 28 JAN 2021
- (A) Fuselage - Disassembled removing all fabric, components, parts, vertical stabilizer, and hardware IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Many reference photos were taken prior to disassembly to help with reassembly later. These pulleys are a part of the rudder control
This is part of the fuel selector
This is the cockpit side of the firewall. It has many extra holes so a new one would be built using it as a pattern and using Stinson Factory Drawings
The number 1014 stamped into the tube extending from the fuselage where the landing gear mounts. This number is the Stinson Serial Number which is different from the AAF number
You can see the many colors that have been overpainted over the years
DATE: 11 JAN 2021
- (A) Instruments – B-8 Airspeed Indicator SN: 109842 Calibration by Keystone Instrument Services Work Order: 20-0755
- (A) Instruments – Tachometer 7440 SN: AF-42-5005 Calibration by Keystone Instrument Services Work Order: 20-0755
- (A) Instruments – Altimeter 1583-20-A SN: 7527 Calibration by Keystone Instrument Services Work Order: 20-0755
DATE: 01 – 05 FEB 2021
- (A) Fuselage - Media blasted, cleaned, inspected and primed airframe with Air Tech Coatings Epoxy Metal Primer. Coated inside of tubular structure with linseed oil IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Fresh coat of Interior Green epoxy metal primer after frame was stripped and inspected for holes and cracks
There are two plugs in the aft section of the fuselage that allow for lindseed oil to be poured in. The fuselage is then rotated several times to coat the inside of the tubular frame.
DATE: 06 – 27 FEB 2021
- (A) Vertical Stabilizer - Removed fabric, disassembled, cleaned, inspected, removed parts, removed old hardware and performed minor repairs. No Casein glue noted IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Vertical Stabilizer - Cleaned, inspected and primed all metal parts with Air Tech Coatings Epoxy Metal Primer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Vertical Stabilizer - Varnished all wood with two coats Air-Tech Coatings Spar Varnish IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Vertical Stabilizer - Installed parts with new hardware IAW Stinson Factory Drawings 76- Series and T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Some new parts had to be made for the belly
New made wood parts two are side panels in the cockpit while the other is a part that transitions from the fuselage to the vertical stabilizer
DATE: 28 FEB – 21 MAR 2021
- (A) Fuselage – Installed control cables, push-pull rods, felt, trim control and cables, vertical stabilizer, wood side panels, recognition light panels, stringers and necessary hardware IAW Stinson Factory Drawings 76- Series and T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Fuselage - Covered, taped, rib stitched and primed IAW Air-Tech Coatings STC# SA7965SW, Stinson Factory Drawings 76- Series, T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956 and AC 43.13-1B Chapter 2 Sections 1-4
- (A) Landing Gear – Cleaned, inspected, and primed with Air-Tech Coatings Epoxy Metal Primer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
Engine disassembly at Amblin Antique Air
Engine disassembly at Amblin Antique Air
In order to cover the fuselage, two lengths of fabric are fitted, marked and pinned on both the top and bottom. The fabric is then removed and stitched along the spine and belly centerline. It is then slid from the tail back on to the fuselage. This requires removing and installing the vertical stabilizer several times.
Rib stitching is required in this area to ensure that the fabric takes its proper form as it transitions from the fuselage to the vertical stabilizer
Note: Next time I do this I would ensure the vertical stabilizer is covered with fabric before ironing the fabric on the fuselage
There are no interior fabric or panels so you will see the back side of the fabric and the frame inside the cockpit when complete.
This is the wood frame for the Recognition Lights that will be installed.
Wood panel for the Top Recognition Light
Alot of taping is required in the cockpit to prevent overspray as this area will be highly visable when complete.
Fuselage is primed, all primed areas will be lightly wet sanded to smooth out the finish and prep for final paint
DATE: 20 MAR 2021
- (E) Oil Cooler – Oil Cooler B3678 SN: 1642 Overhauled by Pacific Oil Coolers Service Inc. Work Order: 143857
DATE: 27 MAR – 20 APR 2021
- (A) Horizontal Stabilizer, Elevator, Rudder, Wings Flaps, Ailerons, Doors - Removed fabric, disassembled, cleaned, inspected, removed parts, removed old hardware and performed minor repairs. No Casein glue noted on wooden parts IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Horizontal Stabilizer, Elevator, Rudder, Wings Flaps, Ailerons, Doors - Cleaned, inspected and primed all metal parts with Air Tech Coatings Epoxy Metal Primer IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Horizontal Stabilizer, Doors - Varnished all wood with two coats Air-Tech Coatings IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Horizontal Stabilizer, Elevator, Rudder, Wings Flaps, Ailerons, Doors - Installed parts with new hardware IAW T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Horizontal Stabilizer, Elevator, Rudder, Wings Flaps, Ailerons, Doors - Covered, taped and primed IAW Air-Tech Coatings STC# SA7965SW, Stinson Factory Drawings 76- Series, T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956 and AC 43.13-1B Chapter 2 Sections 1-4
Horizontal stabilizer is also made of wood. It is being cleaned before appling two coats of varnish
DATE: 08 – 16 MAY 2021
- (A) Fuselage, Horizontal Stabilizer, Elevator, Rudder, Wings Flaps, Ailerons, Doors, Gear Legs – Sanded, cleaned, prepped and painted three coats IAW Stinson Factory Drawings 76- Series and T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956
- (A) Landing Gear – Installed IAW Stinson Factory Drawings 76- Series, T.O. 01-50DB-2 – Maintenance Instructions – L-5, OY-1 15 Apr 1956 and AC-43.13-1B Chapter 9 Section 1
Pilot door, cleaned and varnished prior to covering
Covered in fabric, the next step will be to prime and wet sand before final coat
Horizontal Stabilizer and Elevator painted with two tone camouflage on top and neutral grey on bottom per Stinson Factory Drawings which show the exact pattern to be used.
Rudeder in two tone camouflage patten
There is only the area on the vertical stabilizer that gets the Medium Green camouflage added. The bottom of the fuselage is painted Neutral Grey
Aileron in two tone camouflage
Flap in two tone camouflage
Bottom of wing in Neutral Grey
Top of wing in two tone camouflage
With shock struts added, The fuselage is on its legs
Recognition Lights installation
Recognition Lights Red, Green, Amber. These can be turned on or off one or more at a time. They can also be flashed using a morse code switch. The lights were used to identify friendly aircraft and to send messages to ground troops
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