DC-3 Restoration Proposal

Background

It is quite unbelievable to think the SAAF had 50 DC-3’s flying in one formation for the 50th anniversary of the DC-3 in 1985. During the last five years the numbers have diminished drastically and today, only four piston-powered DC-3’s remain flying in South Africa, one of which is a military aircraft. (There are more Harvards than DC-3’s flying in SA today!!)

As aviation enthusiasts we are continuously on the lookout for someone who would be prepared to make a contribution towards the preservation of these beautiful old aircraft. It is for this reason that we propose a  purchase of one of the two DC-3’s which we have available.

This serves to be a proposal with only rough estimates of work to be done and cost for the project. Final cost of the entire project can only be calculated once a decision had been made on which airframe to use and detailed specifications by the new owner for the interior, avionics and paintwork.

The Aircraft

Two aircraft are available.

1) DC-3A. ZS-KEX: This aircraft is truly a collectors item as it came of the production line at the Santa Monica plant on 19 April 1938, and would therefore, when it is flying again, be one of the oldest DC-3’s still flying anywhere in the world.

ZS-KEX    SER # 2008   Wonderboom Airport 1987

2) C47/DC-3 ZS-NTE: A low time C-47, which is structurally still in very good condition as it has only done 12,500 total flight hours since new in 1943.

ZS-NTE      Rand Airport 2002

Restoration

Both aircraft will be delivered fresh out of a D-Check (Major) i.e. it will have 2,800 hrs before the next major check. It will have a valid SA CAA Certificate of Airworthiness (C of A)

1) Structure:

a) Airframe:

Both aircraft have been paint-stripped and X-rayed and all corrosion had been removed. Structural repair work had been done to remove most of the big dents on the skin. The smaller, possible hail dents on top of the crown would not be removed unless the new owner so wishes, which would then require a new quotation. (Very few hail dents on ZS-KEX only).

Both structures are now in excellent condition. A lot of structural repair work had been done already on ZS-KEX, including the manufacturing of complete components such as the vertical stabiliser. A photograph of the stabiliser is contained below.

 New Vertical Stabiliser on ZS-KEX

b) Cockpit:

  The entire cockpit, including the windshields, control pedestal and the pilot seats would be restored.

c) Avionics:

  A digital King Avionics pack, suitable for a DC-3 type of operation will be installed.

d) Interior:

  A completely new cabin interior would be installed into ZS-KEX. Apart from the sidewall panels, the rest of the interior of ZS-NTE would also be new. A choice of 28 high density or 21 low density seating configuration could be used. A choice of newly overhauled B747 economy class seats or lightweight original DC-3 seats could be fitted in seven rows, two on each side of a single isle. Each seat row would have a window.

The seats would be finished in leather. All materials would be approved.

e) Galley:

  The galley would be equipped for modern bins in order to provide for a cold business class service only. The galley would be situated in between the passenger cabin and the cockpit area, on the left hand side of the isle.

f) Toilet Area:

  The toilet area would consist of a flushing toilet (Caravan type) with a stainless steel hand wash basin. Only cold water would be available.

2) Engines: (TBO on these engines are 1200hrs)

a) ZS-KEX

Newly overhauled, Quick Engine Change (QEC’s) modules would be fitted, from the engine firewall forward. This would include all the engine components, engine mounts, diaphragm, oil tank and oil cooler.

b) ZS-NTE

i) Left engine 200 HRS Since Major Overhaul (SMO) ii) Right engine 800 SMO.

3) Propellers:

     a) ZS-KEX

      Two zero timed, overhauled propellers would be fitted.

b) ZS-NTE

  i) Left prop 720 before next overhaul  ii) Right prop 1350 before next overhaul

4) Electrical System:

a) ZS-KEX.

The entire electrical wiring would be replaced by a newly installed wiring system.

b)   ZS-NTE

A complete inspection and overhaul of the system will be carried out.

5) Fuel System: 

The entire fuel system would be overhauled, including the fuel tank booster pumps.

6) Hydraulic system:

The entire hydraulic system would be overhauled.

7) Flight control system:

All flight-controls would be structurally inspected and repaired before being re-covered with the latest approved materials.

8) Landing gear:

The whole landing gear would be overhauled and new tyres and tubes would be fitted to the main gear and the tail wheel.

Maintenance Base:

SAS’s AMO is based in its own hangar, Hangar 5 at Rand Airport, Germiston. This hangar is big enough to accommodate aircraft as big as a B737, and the restoration will be facilitated in this hangar.

HANGAR

Hangar 5, Rand Airport 2003

A dedicated enclosed area in the back of the hangar will be equipped for restoration work of aircraft.

If required a web cam could be installed which would make it possible for anyone to view progress of the restoration process.

Estimated Cost:

1) ZS-KEX  R2, 250,0002) ZS-NTE  R1, 750,000

Notes:

1) ZS-NTE will require approximately 4 months to complete and ZS-KEX will require approximately 7 months.2) A formal agreement will have to be concluded before work could commence.3) A deposit of 30%, will be payable on signing of the agreement.4) The balance of payment will be required as work on the aircraft progresses.5) It is maybe worth noting that there are many DC-3’s available at considerably lower prices. The difference in prices is definitely not only in the cosmetics but lies in the fact that these aircraft are completely overhauled, comes with a valid, FULL C of A and can operate in the public category, carrying full fare paying passengers.

In summary we would like to make the following comment. Making lots of money with propliners is simply no more possible otherwise lots of people would have done so. However, DC-3’s are really getting scarce and will, in our opinion, appreciate in value in the future.  Flying them is absolutely MAGIC!!

Thank you very much for the opportunity to submit this proposal.

Capt. Flippie Vermeulen: CEO Springbok Aviation Services SA. (Pty) Ltd.