Restoring and Maintaining Douglas C47 Dakota KG651
Local companies support the restoration and maintenance of KG651
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Last year, the Dakota moved into its purpose built hangar. Its condition had deteriorated in spite of our best efforts, as all inactive aircraft do outside. The restoration and conservation of this 77 year old aircraft is an ongoing task and there are always jobs to do to improve the display as well as maintain and conserve it for the future. With the Dakota now housed out of the weather its long term future looks more assured and the restoration work can be undertaken in much warmer and drier conditions. This work has all been undertaken by our team of volunteers with some invaluable support from local businesses that we would like to call out.
The construction of the Dakota Hangar started in September 2019. The hangar was built around the Dakota (the framework is actually a recycled and extended barn donated by Dyson Farms, or Beeswax as it was then) as it would be impossible to move it in after construction. The main contractor, Skinns of Walcott, did a fantastic job of not denting the Dakota when working all around it; really not an easy task at times! Progress was hampered by bad weather and Covid but Skinns recently returned to site to install the walls so the aircraft is now properly sheltered for the winter of 2021 / 2022. |
The Dakota hangar is a large financial and logistical undertaking for a small museum that is funded mainly by donations and run by unpaid volunteers. We have asked for help from many sources and we have received several generous donations from supporters in the UK and abroad. We have used local businesses and contractors as much as possible and several have been very generous. Recently, Witham Oil & Paint very kindly donated the two pack epoxy paint for the newly laid concrete walkways after we asked them for some advice about how to finish the concrete paths for the public display area.
As the hangar is large, most jobs tend to be large (and expensive) as well. After we were given detailed instructions for preparation and application of the paint it took our floor painting team of six, two full days to complete the task but it looks splendid now. Project leader Ian Brett said “We have been very fortunate with many local firms supporting our efforts. A big thank you to Witham Oil & Paint for all your help, it has been very much appreciated.”
Check out the video below to see our volunteers transforming the hangar floors using the materials supplied by Witham Oil & Paint.
As the hangar is large, most jobs tend to be large (and expensive) as well. After we were given detailed instructions for preparation and application of the paint it took our floor painting team of six, two full days to complete the task but it looks splendid now. Project leader Ian Brett said “We have been very fortunate with many local firms supporting our efforts. A big thank you to Witham Oil & Paint for all your help, it has been very much appreciated.”
Check out the video below to see our volunteers transforming the hangar floors using the materials supplied by Witham Oil & Paint.
The History of KG651 - Incident involving KG651 when flying as civil aircraft G-AMHJ
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If you have visited Metheringham Airfield Visitor Centre or follow the restoration of our Douglas Dakota KG651, you will know that the aircraft is displayed at the museum in her RAF military “olive drab” paint scheme with serial number KG651. This represents how the aircraft would have looked whilst in RAF service from 1944 to 1946. Thereafter, she spent most of her working life in civilian clothes under the civil registration G-AMHJ. This is why we offer our Dakota key rings in both military and civil versions as many people have an interest in, or association with, the aircraft from its time flying for various civil airlines. One such person is Mike Le Galle who contacted us after purchasing a G-AMHJ key ring to say he had a story relating to our aircraft. In turns out Mike flew G-AMHJ whilst it was in service with Intra Airways and to say his story was interesting would be an understatement so, in Mike’s own words, here it is............
“4th April 1978 was a date I will not forget. I was a Captain with Intra Airways in Jersey, Channel Islands, and that day our first flight was from Jersey to Staverton (formerly RAF Staverton and now Gloucestershire Airport) then back to Jersey. Myself and F/O Clive along with CC Fiona pre flight checked DC-3 G-AMHJ and we had around 25 passengers and around half fuel for the short flight to Staverton. History tells us that Intra at the time was one of the last operators to use the DC-3 for scheduled passenger operations in Europe. The take off and flight up to Staverton from Jersey was normal and we arrived overhead the Staverton NDB beacon ready for the non-precision approach. The weather was not brilliant however and the cloud base was around 600ft with easterly surface winds which allowed the approach to runway 09 at Staverton. Just as we arrived overhead the NDB beacon there was a huge bang accompanied by lots of vibration, which, as I was handling pilot, felt like a starboard engine failure, as the old pilot adage of ‘dead leg dead engine’ was clear and this along with low starboard engine RPM seemed to indicate the starboard engine. Just to check I asked the F/O Clive to look out his side window and when he looked back at me, he said nothing, but I instantly knew it was the starboard engine, as his expression was one of fear and his face was pale. Only later on the ground did I really realise why his expression had changed. We shut down the starboard engine, increased power on the live port engine and I trimmed the aircraft. Airspeed was quickly dropping, however I managed to get airspeed stabilised at the minimum single engine speed of 86 knots. With the undercarriage up and flaps at 11° down and maintaining airspeed of 86kts, it soon became clear that level flight was not possible, indeed the best we would manage was around 500fpm down. This was turning into our unlucky but also lucky day, as the descent profile from over the beacon was for about 500fpm descent, going 5nm out turning back and 5nm inbound to the runway. This we did, holding full power on the port P&W 1830 engine, just holding the descent profile, and leaving the undercarriage up until we became visual with the runway at 600ft, and landing with only the 11° flap. Staverton in those days had the small passenger terminal at the far end of runway 09, and only a small curved taxiway from the runway, so as luck would have it, I managed to turn right at the runway end, and slide to a parking position without having to use any power. Once stopped, we let the passengers disembark from the port rear door, they must have looked back, but would not have seen the damage to the starboard engine. Clive and myself left and followed them, we walked around to the starboard side, now I knew why Clive had looked so pale. The starboard engine had failed in spectacular fashion; a conrod had snapped pushing the cylinder outwards and destroying the petal cowlings on that side. They had splayed out without detaching from the aircraft thus forming a huge air brake on the outside of the engine. Also, as the propeller feathered it pushed the detached cowlings further back and jamming them in the open position - no wonder we had been unable to hold level altitude. An engineer arrived shaking his head as he put up a trestle and from the inside of the cowling produced a hand full of oil and bits of broken engine. Not long after, the local police arrived and they opened the back of their squad car to show us the broken oily bits of P&W engine, which they had picked up from the B4063 road. Thankfully they had fallen without causing any damage or injuries. After Intra sent a replacement DC-3 G-AMYJ up to Staverton, we positioned as passengers back to Jersey, only to be asked to fly that days' late Jersey-Dinard-Jersey schedule DC-3 rotation with G-AMYJ. The story had a significant twist, as the following day the Chief Piot called me into his office. I thought ‘I’m for it now’, but no, he said ‘Le Galle you keep breaking our DC-3s so we are putting you back on the Viscount as Captain’. I had flown it as F/O, and two days later I was in Sumburgh, flying training for my LHS Viscount conversion. 4th April 1978 remains a significant day for me.” Mike Le Galle, January 2021 |
Mike Le Galle who flew G-AMHJ for Intra Airways in the 1970s.
The damaged cylinder and cowling
Another angle of the damaged cylinder and cowling
This photo clearly shows how the damaged cowling, pushed back through almost 90 degrees, would have acted as an effective air brake!
G-AMHJ on the apron at Staverton ready to fly again after being repaired. You can see the shiny new cowling!
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If you would like to own a piece of aviation history you can buy a Dakota / DC3 keyring here: https://mavc.onlineweb.shop/Douglas_C47_Dog_Tag/p6698945_20521039.aspx
The History of the Dakota and RAF Metheringham's KG651
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The C47 Dakota (Douglas Aircraft Company Transport Aircraft) or ‘gooney bird’ was the air transport ‘workhorse’ of WW2. Developed as a robust militarized version of the DC3 civilian airliner, over 16,000 were built, with production commencing in 1941. General Eisenhower named this aircraft as one of his four “Tools of Victory”. A ubiquitous transport aircraft it carried not only freight such as food, water, ammunition and fuel but also troops. This is exemplified by the aircraft’s role in the airborne operations of Sicily, D-Day, Operation Market and Operation Varsity, the crossing of the Rhine in March 1945. Moreover, empty aircraft returning from combat zones after transporting supplies were also utilized within the evacuation chain, evacuating injured troops to hospitals in the rear areas. Many injured US service personnel requiring repatriation to the USA were evacuated by the Dakotas of US 52nd Troop Carrier Wing from RAF Metheringham. Acting as a supporting airfield and Air Evacuation Centre, the 52nd Troop Carrier Wing predominantly comprised of the following Troop Carrier Groups (TCGs) based at other nearby airfields: 314 TCG (US Army Air Station 538, Saltby), 313 TCG (USAAS 484, Folkingham) and 61 YCG (USAAS 483, Barkston Heath).
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KG651 faces up to the "Beast from East" at RAF Metheringham during the Winter of 2017 / 2018. The aircraft has since been moved under cover to protect it from the worst of our Winter weather. See below for more information on how to support this project.
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The first such evacuation was on 15th May 1944 when 19 patients from the nearby US Army 7th and subsequently 162nd General Hospitals, Nocton (https://www.med-dept.com/unit-histories/162d-general-hospital/), were flown in a single Dakota to Renfrew, Scotland. This marked the start of RAF Metheringham as the recognized Air Evacuation Centre for this US Army General Hospital. Patients were flown from RAF Metheringham to either Renfrew or the Transatlantic Military Air Terminal at Prestwick for onward air repatriation to the USA via Greenland and Newfoundland.
Before the end of the war, air evacuations by up to 9 Dakota aircraft at a time would occur from RAF Metheringham, on at least 30 occasions. Between 15th May 1944 and 8th May 1945 it is known that at least 1693 US service men were medically evacuated by air from Nocton to the USA, starting their journey at RAF Metheringham.
In only two documented instances were casualties received by air at RAF Metheringham direct from the combat zone; in neither case were the aircraft or casualties expected. On 1 December 1944, 11 Dakota aircraft landed evacuation 300 ambulatory injured troops directly from France. Similarly, on 14 April 1945, 5 Dakotas carrying 17 stretcher and 83 ambulatory cases enroute to Renfrew, Scotland, were forced to land at RAF Metheringham. There was approximately 30 minutes notice in which to prepare to transfer these patients to the wards at Nocton Hall, 7 miles away. The patients returned to RAF Metheringham the next day to continue their onward journey back to the USA.
Whilst the Dakota in MAVC’s collection is not one that was used at RAF Metheringham, it was bought and put into active service by the RAF in 1944. It was then sold in November 1946 and converted into a civilian aircraft, finally being retired from operation in 2000.
Extracts taken from ZN Newsletter written by Group Captain Ian Hindle JP, PhD, MSc, BDS, FDSRCS, FFDRCSI RAF (ret).
Before the end of the war, air evacuations by up to 9 Dakota aircraft at a time would occur from RAF Metheringham, on at least 30 occasions. Between 15th May 1944 and 8th May 1945 it is known that at least 1693 US service men were medically evacuated by air from Nocton to the USA, starting their journey at RAF Metheringham.
In only two documented instances were casualties received by air at RAF Metheringham direct from the combat zone; in neither case were the aircraft or casualties expected. On 1 December 1944, 11 Dakota aircraft landed evacuation 300 ambulatory injured troops directly from France. Similarly, on 14 April 1945, 5 Dakotas carrying 17 stretcher and 83 ambulatory cases enroute to Renfrew, Scotland, were forced to land at RAF Metheringham. There was approximately 30 minutes notice in which to prepare to transfer these patients to the wards at Nocton Hall, 7 miles away. The patients returned to RAF Metheringham the next day to continue their onward journey back to the USA.
Whilst the Dakota in MAVC’s collection is not one that was used at RAF Metheringham, it was bought and put into active service by the RAF in 1944. It was then sold in November 1946 and converted into a civilian aircraft, finally being retired from operation in 2000.
Extracts taken from ZN Newsletter written by Group Captain Ian Hindle JP, PhD, MSc, BDS, FDSRCS, FFDRCSI RAF (ret).
Winter 2020 Update
It's been a long time since the last update on progress with the Dakota hangar at Metheringham Airfield Visitor Centre. As with many similar attractions the museum didn't open this season because of the COVID 19 restrictions. Progress with the hangar build also came to a halt for several months, firstly because the site was waterlogged after the extremely wet end to 2019 and then when it did dry out, the first lockdown happened.
Skinns, the local contractor building the hangar, have struggled to catch up with work time lost over the lockdown but have made some progress with the hardcore for the concrete pathway inside the hangar. The roof is complete, and gutters are taking the rain water away from the site now. In the next few days, we hope to have some concrete pathways and side panels fitted. That will be all we can fund for the next few months, the hangar end panels will not be fitted until funds are available, hopefully before next Winter. Our fundraising took a big hit this year with the museum unable to open, most of our income is from visitors in the Summer season.
Although we were unable to do much work on the Dakota over the Summer, we have been busy trying to obtain a pair of propellers for the Dakota. The owner of the props we had on loan took them back in early 2019 leaving it looking rather sad with no props. We had high hopes for the manufacture of some replicas, but this wasn't to be. In the meantime, we asked around any possible sources and were helped out by our friends at Coventry Airport. We have had a few small items from them before to help with the display of KG651, many thanks to the team restoring another Dakota to flying, "Night Fright" https://www.night-fright.com . We hope to see it flying again soon, on completion of the mammoth restoration project. The prop was soon assembled and fitted to the left engine, a big improvement. We need to locate another prop now. Although many thousands were made in the 1940’s and 50’s they are a little thin on the ground in the 2020’s.
With the Dakota under a roof for the first time in many years it has weathered the wet 2019 Winter well and seems to be fully dried out now. We plan to restore the paintwork back to a WW2 European theatre dark green finish with grey undersides at some point as it has faded to a rather pale version in the years it has stood outside at Metheringham. We have chosen to commemorate both the RAF and USAAF using paint schemes that will best represent the history of the aircraft and those Dakotas that operated at RAF Metheringham in WW2. Some decisions will have to be made on how to best display KG651 within the weatherproof but restricted space of the hangar.
For more information on the museum and KG651 and to make a donation visit: https://www.metheringhamairfield.co.uk . The popular key rings, made from a section of wing skin (removed during a repair), are still available from the website shop, along with many other things. We now do a G-AMHJ version as well to mark KG651’s civilian life and a "dog tag" version of both. An ideal Christmas present for the person who has everything.
Skinns, the local contractor building the hangar, have struggled to catch up with work time lost over the lockdown but have made some progress with the hardcore for the concrete pathway inside the hangar. The roof is complete, and gutters are taking the rain water away from the site now. In the next few days, we hope to have some concrete pathways and side panels fitted. That will be all we can fund for the next few months, the hangar end panels will not be fitted until funds are available, hopefully before next Winter. Our fundraising took a big hit this year with the museum unable to open, most of our income is from visitors in the Summer season.
Although we were unable to do much work on the Dakota over the Summer, we have been busy trying to obtain a pair of propellers for the Dakota. The owner of the props we had on loan took them back in early 2019 leaving it looking rather sad with no props. We had high hopes for the manufacture of some replicas, but this wasn't to be. In the meantime, we asked around any possible sources and were helped out by our friends at Coventry Airport. We have had a few small items from them before to help with the display of KG651, many thanks to the team restoring another Dakota to flying, "Night Fright" https://www.night-fright.com . We hope to see it flying again soon, on completion of the mammoth restoration project. The prop was soon assembled and fitted to the left engine, a big improvement. We need to locate another prop now. Although many thousands were made in the 1940’s and 50’s they are a little thin on the ground in the 2020’s.
With the Dakota under a roof for the first time in many years it has weathered the wet 2019 Winter well and seems to be fully dried out now. We plan to restore the paintwork back to a WW2 European theatre dark green finish with grey undersides at some point as it has faded to a rather pale version in the years it has stood outside at Metheringham. We have chosen to commemorate both the RAF and USAAF using paint schemes that will best represent the history of the aircraft and those Dakotas that operated at RAF Metheringham in WW2. Some decisions will have to be made on how to best display KG651 within the weatherproof but restricted space of the hangar.
For more information on the museum and KG651 and to make a donation visit: https://www.metheringhamairfield.co.uk . The popular key rings, made from a section of wing skin (removed during a repair), are still available from the website shop, along with many other things. We now do a G-AMHJ version as well to mark KG651’s civilian life and a "dog tag" version of both. An ideal Christmas present for the person who has everything.
Summer 2020 Update
As the curatorial team and Dakota team have recently returned to site, our contractors have been able to complete the concreting of the stanchions and they are in the process of laying the three metre wide walkway around the inside of the building. They will also create a pathway from the walkway to the aircraft's cargo door, which will greatly improve access for volunteers and visitors alike.
We have also agreed with them to proceed with the fitting of the two side walls and to install guttering, which should prevent further flooding and make the building reasonably weatherproof as Autumn approaches. Unfortunately finances do not permit us to progress any further in this calendar year, but at least the aircraft will be properly undercover and available to visitors when we reopen in 2021. If you would like to donate to the Dakota Hangar fund why not buy a Dakota key ring or dog tag here: https://mavc.onlineweb.shop/Gifts/cat6698946_4610017.aspx. Alternatively you can make a donation to the Dakota Hangar Project here: https://mavc.onlineweb.shop/Dakota/cat6698946_4602220.aspx.
We have also agreed with them to proceed with the fitting of the two side walls and to install guttering, which should prevent further flooding and make the building reasonably weatherproof as Autumn approaches. Unfortunately finances do not permit us to progress any further in this calendar year, but at least the aircraft will be properly undercover and available to visitors when we reopen in 2021. If you would like to donate to the Dakota Hangar fund why not buy a Dakota key ring or dog tag here: https://mavc.onlineweb.shop/Gifts/cat6698946_4610017.aspx. Alternatively you can make a donation to the Dakota Hangar Project here: https://mavc.onlineweb.shop/Dakota/cat6698946_4602220.aspx.
Winter 2019 / 2020 Update - Location, location......re-location! Hangar that Dak!!
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Late Summer of 2019 saw the final journey of KG651 from its position on the hard standing where she has been for the last 4 years to the location of the new purpose built hangar.
The design of the hangar is such that it was necessary to move the aircraft into position in the partially built frame and then complete the frame around her. The construction team (Skinns of Walcott) first marked out the hangar ground plan and dug out the foundations in the support post positions, then erected the supports at the back of the hangar. The Dakota team, very ably assisted by the Skinns construction team and other volunteers, then moved KG651 into position. An interesting exercise as the towing vehicle and the aircraft had to pass over the holes dug for the hangar supports and also avoid the support posts already in place. Strategically placed ramps were used to get over the holes and lots of shuffling eventually got the aircraft into position. Some trimming of the memorial garden hedge was also necessary to avoid damage to the starboard wing during the manoeuvring; apologies to our gardener Jack! The frame of the hangar was then completed and the roof was installed. This took some time as the weather was not kind to us. This phase of the build now needs only the levelling of the ground and laying of the concrete walkway around the perimeter to be complete. This is weather dependent but should be completed before the museum opens for the 2020 season. At this point it should be possible to allow public access again - important as the Dakota is a very popular part of the museum. The next phase will be the completion of the hangar by the addition of the walls, entrance door and electrical supply. The museum is currently making great efforts to raise funds for this next phase. Your support would be greatly appreciated. Should you wish to contribute to the Dakota project or the museum in general it is now possible to do so through the museum website's online store. As part of our fundraising effort we are also selling limited edition Dakota key rings made from a panel removed from KG651. This is an ideal and quite unique gift for any aviation enthusiast. Find out more here. All proceeds of key ring sales go to the hangar project. |
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Raising funds for the new Dakota Hangar and Dakota Restoration
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Our Douglas Dakota KG651 is one of the star attractions at Metheringham Airfield Visitor Centre as it provides a unique opportunity for visitors to climb inside this remarkable WW2 workhorse and even sit in the cockpit. The restoration of Dakota KG651 to represent a 1944 RAF Dakota is a significant ongoing project at Metheringham Airfield Visitor Centre. This work is somewhat hindered by the fact that until now, KG651 has stood outside, exposed to the elements all year round. Apart from the obvious effects of weathering on the airframe and engines, being outside means that it is almost impossible to carry out restoration work in bad weather and through the very cold Winter months. Work is now underway to build a hangar for the aircraft which has been moved a small distance to a new position on the site where the new hangar will be built around it. Work has already started and you can see the foundations for the hangar in the photo (right).
In addition to fundraising for day to day activities at The Museum, we are in desperate need of additional funds to support the building of the new hangar. Back in July we were delighted to host representatives of North Kesteven District Council Economic Development Programme when a cheque was presented to Andrew Scoley of The Friends of Metheringham Airfield by Councillor Richard Wright of North Kesteven District Council. These much needed funds will contribute to the completion of the hangar to house our precious Dakota but we still need at least £20,000 to complete the project. If you can help with the preservation of this important aircraft, any donation, large of small would be gratefully received. Please see our Membership & Donations page for more information. You can now donate to our Dakota Hangar Project via debit or credit card or PayPal through our online store here. Alternatively, you can donate via text straight from your mobile. To donate £5 just text "DAKOTA" to 70085. Texts cost £5 plus your normal network charge. If you are interested in becoming a corporate sponsor, please contact us using the contact page. |
The foundations of the new hangar can be seen in the right of this photo (kindly supplied by Vince Gratrick).
Councillor Richard Wright of North Kesteven District Council presents a cheque for £5000 to Andrew Scoley of The Friends of Metheringham Airfield.
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The restoration of KG651 to represent a 1944 RAF Dakota continues throughout the year but the closure of the museum to visitors over the winter gives us a chance to do some larger tasks without disruption. With the aircraft being kept outside this means we are at the mercy of the weather. Luckily this winter has not been too harsh, although there were some very cold working days and a former airfield can be a bleak place in Winter. |
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Our small band of volunteers has almost completed the essential inspections and anti-corrosion treatment of the underfloor areas. This involved lifting several floor panels for access, a lot of cleaning, some rectification and applying ACF50 before refitting the floors. The airframe is generally in remarkably good condition form a corrosion point, for a 75 year old that was built for an intended life of considerably less than that. We inspected the control cables while we had access to them, with a view to restoring them at a later date. Some are missing or damaged so that will be a lengthy task at some point and maybe not cost effective for a static ground display aircraft.
Some further work has been done in the Radio and Navigators positions to make them more complete. We now have some heating and ventilation trunking in place. The original hoses were perished beyond use so a more modern substitute has been used and “aged” so it doesn’t look too out of place. We have completed the interior LED lighting to improve things on dull days. |
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In March the team visited Coventry Airport to have a look at the progress with the rebuild to flying condition of a 1944 C-47A called “Night Fright”. We have helped with its restoration by exchanging some surplus items, both teams have gained some needed parts. It is good to see these parts will help another Dakota fly again. Our Dakota had an oil cooler fairing missing, not an easy part to fabricate. We now have the fairing fitted and that large visual hole is filled. We hope to retain our association with the Coventry team in the future.
Unfortunately not all the progress has been positive, as we have degraded our display by removing the Dakota’s propellers. We have had to return our loaned propellers to their owners after they terminated the loan. We have tried to acquire some affordable replacements without success, up to now, but are following up some leads and hope to have the Dakota looking less like a jet and more as it should again soon. |
As we approach the off season of Autumn / Winter 2019/2020, we hope to step up restoration work on KG651 and this is something that should be made a whole lot easier with the construction of our new hangar. This big project is well underway but we need at least another £20,000 in order to complete it.
