Spirit of Douglas Flies Again

Update provided by Captain Connell Weston;

The Spirit of Douglas DC-3 has taken to the skies once again following her much-needed right-hand engine change.

Paul, alongside four engineers from JEM Aviation Omaka — Jay, Deane, Jeremy and Freeman — with the capable assistance of apprentice engineer Liam, successfully completed the engine replacement along with routine maintenance work and subsequent test flights.

Wednesday 13 May

I arrived at the Garden City Helicopters hangar to find the JEM team gathered around the right-hand engine, strategising the removal of the propeller.

We eagerly awaited the arrival of a much-needed forklift, essential for the heavy lifting that would dominate the coming days. Once in place, and with the aid of a specially designed jig to keep the propeller secure and stable, the propeller was carefully removed and gently placed to one side.

Thursday 14 May

I collected Paul from Christchurch Airport following his long journey from Portland via San Francisco and Auckland. After a quick coffee and bite to eat at the terminal, we headed straight to the hangar.

Following a post “toolbox strategy meeting” with all involved, the engine was clear of the airframe by 1130 — just two hours after Paul’s arrival at the hangar.

The engineering team then got to work transferring numerous components from the old engine to the new one: generator, starter motor, carburettor, engine mounts and associated framework etc. Not forgetting the propeller governor, nestled between the magnetos on the front of the engine, which provided Deane with no shortage of entertainment and frustration.

Friday 15 May

Another 0730 start saw preparations continue on the new engine while it was still conveniently positioned at eye level. Paul took the opportunity to replace several components with newly reconditioned units, maintaining a preventative rather than reactive approach to maintenance.

By 1530 the new engine had been secured to the firewall of Spirit of Douglas — a phenomenal achievement by the team.

Special thanks must also go to Morgan and Paul, who had spent 4–5 weeks earlier preparing the replacement engine, meaning much of the disassembly work had already been completed before the engine even arrived.

By the end of the day, with precise forklift operation from Jeremy, the propeller had been carefully guided back onto the propeller shaft. A solid effort by all involved, interspersed with occasional pauses to admire the Emirates A380 and other aircraft operating nearby — a rare and impressive sight for much of the Omaka engineering team.

Saturday 16 May

Another 0730 start saw me tangled up in the intricacies of changing components within the cowl flap system, all under the close observation of Paul.

Meanwhile, the engineering team busied themselves connecting and torquing a multitude of fittings — often quoting delightfully old-school maintenance manual references such as “a 185 lb man on a 4-foot pipe” to achieve the correct torque settings.

The propeller was then reset to the correct angle, a setting critically important for safe flight operations.

At 1400, Will from Garden City Helicopters connected the Mototok to the tailwheel of our old lady and pushed her into position for the first engine run.

I occupied the left seat while Paul sat closest to the new engine and coaxed her into life. The unmistakable throb of the Pratt & Whitney R-1830-94 was absolute music to our ears.

After a thorough warm-up, the propeller governor was put through its paces to ensure proper function and accurate settings. A few minor adjustments were required, but overall it was a tremendous success.

Sunday 17 May

We returned to the hangar at a similar time to complete adjustments identified during the previous day’s engine runs and functional checks.

With the engine cowlings now installed, there was very little preventing us from finally breaking the clutches of terra firma once more.

At 1425, Paul — a master of his trade — took Spirit of Douglas back to where she truly belongs: the skies.

After a brief 15-minute flight, we touched down once again. A few further adjustments to the propeller governor were still required before pulling her back into the hangar for the night, with plans to fly her to Omaka the following morning.

A huge thanks,

JEM Aviation Omaka

Jay, Deane, Jeremy and Freeman

Liam, apprentice Christchurch based engineer.

The entire GCH team with special mention to Alister for facilitating the use of many tools and test units.

‍

Spirit of Douglas Exterior images - captured by Jake Holyoake in Omaka

‍