You
have to get around Dreadnought if you want to win Reno.
That isn’t as easy as
it sounds, and few racing planes have done it on a consistent basis. If perennial
favorites like Strega, Dago Red (right) and Rare
Bear are running well, they’ll be out in front. Mike Brown will be
there, too, in September Fury. Tom Dwelle and Critical Mass have
done it, and finished third last year; his best finish ever. They have
the horsepower and speed to win.
But you’ve got to get around Dreadnought.
History Lesson
Sea
Furies have been raced at Reno and various other events for a long time.
Mike Carroll, and later Sherm Cooper, raced the gorgeous Miss Merced (left)
beginning in 1965. Ormond Haydon-Baille raced his stock Fury in 1971,
and Lloyd Hamilton raced not only his stock Fury, but also came up with
a racing version. There were a handful of others, too. With the stock
Centarus engine, the British fighter would never be a top unlimited
contender, but it ran well in the cross country competitions.
So... What if the airframe got big horsepower? What would happen
then? The wing was already an excellent choice for a fast race plane,
and the airframe was sized for carrying enough consumables. If a larger
engine was going to be used, the increased fuel consumption, ADI and
water flow rates would mean a lot of liquid would have to be carried.
The idea originally came
from Bill Kerchenfaut (left) and the late Sherman Cooper back in the
1970s. They ran the yellow and flame draped Fury around the pylons with
a degree of success until an engine failure forced the plane into a
desert belly landing. They had an idea that a R-4360 would look good on
the front of a Sea Fury, and that the result would go like stink.
Time went by, but nothing was ever done. Cooper would be killed in an
accident, and Miss Merced was sold. Bill Kerchenfaut would go on
to be crew chief on a number of successful racers. Nobody would fulfill
the Sea Fury/R-4360 prophecy.
Enter The
Chino Kids. In 1982, they were making an F2G Super Corsair (right) racer
out of an old F4U-1 they had in their yard. A massive R-4360 was bolted
onto a custom engine mount, a Skyraider prop was installed, and flight
tests began. Frank Sanders flew chase in his stock two-seat Sea Fury
(below) during a test flight out of Chino prior to Reno. Jim Maloney, at
the controls of the Super Corsair, put power to the engine for the first
time during that flight.
The 4,000
hp. racing Corsair pulled away from the stock Sea Fury like it was tied
to a post. Sanders, from his cockpit, watched as the Super Corsair
marched away at a dry power setting of 50 inches and 2,800 rpm. Years
later, Frank’s son Brian would recall his dad’s impression. "My
dad said, with all due respect, ‘If that big, draggy piece of shit
will do that, think what a new, cleaner airframe like a Sea Fury would
do!’"
Exactly. Sanders huddled with his sons Dennis and Brian... "You
want to go air racing?" Brian thought at the time, "We had
nothing better to do..."
But first,
Sanders (right, with wife Ruth) had to know if the airframe could even
handle that type of horsepower. Engineer Bruce Boland, of Lockheed and
air racing fame, was brought in to do the load calculations, taking into
account horsepower, gyroscopic, and G loads the engine would generate.
"Stout for hell," was his reply. Green light.
If You Build It, You Will Win
The racer that would become Dreadnought traces its lines back
to two separate airframes. The first was a two-seat German Air Force
target tug registered D-COCO. It was imported to the United States in
1977 by John Stokes. One year later, the plane was sold to Bill
Harrison, who raced it in 1978 as Wasa Hooker. Shortly after the
races, Robert Friedman acquired the aircraft, but was killed in it
during a takeoff accident two weeks after he bought it.
Sanders had bought the wreck in 1979, as well as another two-seat
Fury airframe from Rangoon. Sanders told the seller if he could get the
plane to California, he would buy it. Low and behold, the airframe
arrived in California and the deal was made. The initial idea was to
build up a trainer from the airframes for sons Brian and Dennis. That
idea went out the window when the Super Corsair walked away from
Frank’s Sea Fury.
Brian
(left), now an accomplished warbird and race pilot, picks up the story.
"When that plane was delivered to us back in ‘78 or ‘79,
there was a good six inches of rat turd in the bottom of it. Rats and
mice had also scurried up the exhaust pipes and ruined the inside of the
engine and its unique sleeve valves. Those are the hardest parts to find
these days." It must have been a sorry sight, but the racer’s day
would come.
Right after Reno 1982, the Sanders family got to work on their
masterpiece. Sanders explained, "We sold our AT-11 and took the
money and bought -4360's from Davis Monthan, some radios and such, and
reinvested it in Dreadnought. It was a hell of a lot of
work." Part and components from the two airframes were combined
into one. "We worked on it from October straight through to Reno.
It was always a mad thrash," Brian said.
Frank
always had strong ideas about engineering a part or a structure, but no
background to back it up. His crew included his sons, one full time
worker and several part time volunteers. Bob Smith, a head
aerodynamicist at Douglas Aircraft, was introduced to Sanders via a car
racing connection. Obviously, a man with this background would bring a
wealth of experience to the program. He did the cooling calculations for
Dreadnought (left, in 1983), and found out they had just enough
flow through the cowling to keep the cylinder head temps just below the
red line. Since heat makes horsepower, this was optimum. He also
verified the inlet and outlet areas for the oil coolers.
"He’d laugh at my
dad," Brian said, "Dad would design something and have Smith
look at it and verify it. Everything firewall forward had to be done
from scratch... The induction inlet shape and the cross section, taking
into account airflow constriction and diffusion, speed, and
pressure..." The engine mount, spinner, cowling and intake and
exhaust pipes were all custom built for the racer.
With a good portion of the airframe work done, the racer was put on
jacks, leveled perfectly with a transit, and plumb bobbed both front and
rear to provide an accurate centerline. The huge radial engine was put
on an adjustable wheeled cart and rolled up next to the firewall. They
plumb bobbed the engine and squared it perfectly with the airframe, and
began to make measurements.
A KC-97 engine mount ring was the first piece to be worked on; all of
the stock attach points were removed, and new points were built. Tubing
would mate the attach ring to the firewall.
"Typical of our dad..," Sanders mused, "When we were
cutting the tubes to connect the engine attach ring to the airframe, he
built a set of tubes out of muffler moly - real thin steel that is easy
to work with. He sat down, measured and cut all the shapes out of the
thin steel. Then he bought aluminum tubing and put that over the steel
and marked it all to cut. Then we slid that over the 4130 tubing, marked
that, and cut that. So, we now have a complete set of patterns if we
ever want to build another mount for a -4360."
With Reno on the
horizon, the airplane was completed and test flown. The hulking racer
was nothing like the sleek racing Mustangs or the compact Bearcat. It
was huge. Typical of British nautical terminology, the racer was
christened Dreadnought, and finished in a silver and red
prototype scheme. She was assigned race number 8, and was registered
N20SF once again. (
Flight Test - Got Stability?
Test flying showed two things. First, it was fast. It was also
unstable The R-4360 is a much longer engine that the stock Bristol
Centarus. Even though the engine was moved back to within a half-inch of
the firewall, the prop line was still 10.5 inches farther forward that a
stock Sea Fury. This is a destabilizing effect on any airplane. Since a
four blade Skyraider unit was being used, the additional 2.5 square feet
of prop area would also add to the problem.
"There were
stability problems," Brian said. But there were fixes for Dreadnought.
"One time dad and I were out working on the stability problem.
He took the airplane and yawed it about 10 degrees, and let go of the
rudder. Normal airplanes would yaw back, but Dreadnought would
stay yawed at 10 degrees. It would fly along sideways perfectly
happy."
While testing over the Chino airport one day, both Frank and Brian
got a huge wake-up call. "Dad locked his feet on the rudder pedals
so they couldn’t move; this was for a gyroscopic test of the
propeller. He banked over into a turn and pulled three G’s, and it
started to swap ends," Brian said. "The thing yawed 15 degrees
nose right, and the tail stalled. You could feel the shudder as the
vertical fin started to stall. Dad jumped on the left rudder, it came
back straight, and he said that was enough! We were only at 6,000 ft.
That wouldn’t have been pretty... tumbling Dreadnought down
over the airport."
Bob Smith, with a
lifetime of aeronautical achievement, shot down some band-aid ideas and
told the Sanders to lengthen the vertical tail by a foot. The end result
was a fixed portion of fin over the moveable rudder and two additional
square feet of area.
"Before we made
it permanent," Brian said, "We did a scab-on with pop rivets
and sheet metal. Dad went out and flew it gingerly because this wasn’t
structural. I went out and I flew it, and so did Dennis (right). It flew
good. Then Lloyd Hamilton came down. He had already flown his R-4360
powered Furias that first year, and knew there were stability
problems. Dad told Lloyd to go out and fly it, and he came back and said
it flew really great. He had yawed 10 degrees and all of this. Dad was
pretty surprised something didn’t rip off. ‘It’s just pop riveted
on,’ Dad said. ‘You were lucky you didn’t tear it off!.’"
Mild Mannered, So to Speak
With the heavier engine up front, the oil tank had to be relocated
aft of the rear seat. Other changes were made to the tankage in the
wings for the fuel, ADI and spraybar water. Hundreds of small changes
were made throughout the aircraft; the canopies were refined, full dual
controls were installed, and better brakes were put in. Overall, the
racer proved to be consistently fast, and its stability problems were
overcome to the point where it’s mild-mannered compared to some other
race planes.
One
of the final issues centered on the Aeroproducts propeller that was
being used. Dreadnought was equipped with an early Skyraider prop
with M-20 blades. These were hollow blades that had the structure built
into the rear half. The front half was brazed on and featured a two inch
flap at the trailing edge. The idea was more blade area meant more
thrust, therefore more speed.
Frank had heard about similar H-20 blades; they have less area and no
trailing edge flange like the M-20 blades. A set was found and installed
on Dreadnought. "We did a bunch of flight testing for the
1985 races. We found them to be 2 mph faster," Brian said.
"That may not seem like a lot, but at the top end, even one mph is
hard to come by."
One change lead to
others, and more refinement. "When we ran that prop, we had some
prop buzz, which you just don’t hear at that gear ratio and that speed
on the Sea Fury," he said. "We went to Bob Smith about it, and
he said the tips of the prop needed to be unloaded. We were running more
pitch, so we needed to load the middle of the prop and unload the tip.
We took a wide chord propeller, left it at full width in the middle, and
trimmed the flange as we went outward. There is no flange at the tip. If
you look at Dreadnought now, you’ll see that the prop has more
of an elliptical shape on the trailing edge. We also got rid of the cuff
at the root. The leading edge is still stock."
Click Here
for Part Two