Lockheed P-38 Lightning Warbird Restorations

It is over two years since Warbirds Online reported on progress on the 3 Lockheed P-38 Lightning rebuilds being undertaken by Robert Grienert and the team at Historical Aircraft Restorations Limited at Albion Park NSW.

Readers will recall that the progress at that stage was concerned with the effort to rebuild the 3 huge wing center sections of the aircraft with the main spars being completed and work accelerating to mount the center sections in the two purpose built jigs to allow for the construction and assembly of the entire sections. This exercise is not for the faint hearted as the P38 center section is a very large and complex construction in its own right let alone the entire wing.

At the time of our recent visit, a remarkable amount of progress was evident with 3 of the center sections very well advanced, two were in jigs undergoing advanced assembly with one also in a smaller transport cradle having been largely completed. Unlike other more numerous types of restorations such as P51 Mustangs and Supermarine Spitfires it is not possible to purchase newly manufactured structural components for the P38. All of the components required to construct a P38 have to be reverse engineered and manufactured in house at the Albion Park facility and to this end Robert Grienert has invested heavily in computer driven technology to design and engineer the components used in the rebuild. A case in point being the complex reinforcing corrugated components used in the wing strengthening sections. These had to be manufactured with great precision and accuracy and the folding of the sections themselves required considerable research. During our recent visit one of the wing centre sections was ready to be removed from the jig and the process is proceeding according to plan with the structurally complete section temporally placed on trestles whilst more of the detailed work is completed.

Another area of great interest during our visit was the progress of construction on the first fuselage “pod” again requiring a great deal of reverse engineering. These structures are manufactured in two sides which are then joined to form the whole pod structure which is then completed and skinned as one piece. The level of precision required to manufacture both halves and have them align together in the jig is extreme.  The two halves mated perfectly on the first try, a testament to the standard of the work performed in the manufacturing process. Work will now concentrate on the completion of the internal structure and fit out with the reskinning then to take place. New forward fuselage gun bay doors have now been researched and designed with the first example having been completed and trial fitted. These complex doors are a work of art in their own right and were built by master panel craftsman Mark Nugent at Dubbo NSW. Mark has a reputation as the “go to” person for difficult panel components on many Warbirds and we previously reported on his work in our news article dated 3 April 2019 Mark Nugent – Warbird Master Craftsman.

The next phase of the wing components are the outboard wings with the 3rd (flying aircraft’s) RH wing underway in a purpose built jig.

Another phase of construction which has commenced is the complex engine/main landing gear nacelles, the first pair of which are now in the jigs being manufactured – these are very large and difficult assembles and the workmanship taken to design and construct them is magnificent.

With the first of the fuselages now advanced the second and third should progress soon and other work take place including more work on the other parts of the P-38 rebuilds such as the ailerons, elevators, horizontal stabilizers and tail booms all of which had previously received attention from the team.  Once sufficient completed components are in hand to construct all 3 of the aircraft final assembly will take place on the first aircraft. As previously mentioned this will be a static “proof of concept” aircraft but constructed to the highest standards followed by the second static airframe and finally the Australian based flying example.

The huge holding of spares and components will allow for a fairly straightforward completion of these Lightnings with fuel, hydraulic electrical systems being readily available as well as fixtures such as seats and glazing for the canopy.

At this stage these 3 Lockheed P-38 Lightnings form the complete project however the capacity and opportunity exist for one or two more should there be sufficient interest in additional aircraft. The provision of engines and propellers for the aircraft is already well in hand with no unexpected delays anticipated.

Whilst all of the work and effort put into these machines is seeing real results it all takes a lot of resources and is a huge task so completion of the aircraft is a while off yet but is in sight. In addition whilst all of this exciting work is under way on the P38s, the workshop is also very busy completing other work for in house projects and external customers. We recently reported that the Bristol Beaufighter flying restoration has recommenced as well as an airworthy P40 under way so there is much to look forward to in this magic cavern of Warbirds.

Warbirds Online will continue to follow the story of these “Fork Tailed Devils” over the next few years, including the first Lockheed P-38 Lightning to fly in Australia since 1945 as part of the great HARS collection.

Warbirds Online extends our thanks Robert Grienert and the team at Albion Park NSW for their help and assistance with our visit.

© John Parker 2020