My '44 Flying Control Dodge

[armyairforce]

A few days ago, I picked up a second BC-348 Receiver. It has had a few modifications which probably aren't authentic such as the metre on the front, but I'm doing what I can to make it look its best. The handles are missing, but I'm hoping to cast some replacements. The aerial quick release terminal had been replaced with a coax socket and one or two knobs have been replaced. The mounting frame on the bottom is also missing.



The new receiver along with the one I got from Rupert

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I have removed the coax connector and made a replacement from brass tube and chemiwood. If I find an original connector, I'll fit it, but for now, this will do.

The brass mounting plate bolts into the back of the panel face using the holes left by the coax fitting. I've built a spring into it so that it functions like the original. It's a bit clean at present, and the original Ground terminal below it, has lost almost all its paint, making the contrast even greater.

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I've also done a bit of minor re-wiring on the receivers ( neither are fully original inside, so I don't feel bad about this ). Of the two bulbs in each receiver band selector, only one of the four worked, and that was a 6 volt bulb. I've ordered some replacement 12 volt bulbs, and rewired the bulb circuits through the master switch, so the lights come on when the master switch is selected on.





Just arrived in the post this morning is several metres of cotton insulated wire, so next time the truck is home, I can begin to wire up the 12v battery, panel lights and radios. No progress this weekend however as I've a wedding to attend shortly.

[armyairforce]

Today I spent a few hours making replacement handles for the new BC-348 radio. Originally I was going to cast them, but the plaster I use for mould making had gone off and wasn't setting properly.

Instead I decided to make them from flat sheet. I didn't have any sheet aluminium, so had to cut some strips from some channel section. This was then annealed, and the main arched folded around a shaped block. It was re-annealed and the end lugs folded over.



The holes were drilled next, then final shaping done with various files, followed by a light rub over with wet and dry paper.



Close up of one of the new handles fitted to the radio prior to painting.

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Both receivers are now fitted with the new 12 volt bulbs, and the new handles painted.



Further progress has been made on the second BC-348 Receiver over the last few days. There were several features that were post war modifications, such as the meter and a couple of switches. I have seen a video on Youtube about modifications to improve the receiver that match the changes made to this radio.

The switches were removed and small aluminium discs cut and filed to fit the holes. The meter left a large hole, so this was just covered over with a thin aluminium panel.

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After trial fitting, the two discs and the square panel were all etch primed, followed by a hammered finish black.

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Both the new receiver and the original one had the incorrect switch on the AVC/MVC control. On the new receiver, there was a rotary control and an additional switch had been fitted. The switch was removed and the hole filled as shown above, and both of the rotary switches removed. This is how they looked before.

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Two new switches were machined from aluminium. The main bodies were turned on my lathe, while the arm cut and filed from flat sheet which was then welded on. The main body was then drilled and tapped for an M3 screw and a bolt cut down and slotted to form the set screw that holds the assembly in place.

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BC-348 Mounting Plate.

As can be seen in the picture below, the mounting plate is missing. This plate connects the receiver housing to the FT-154 mounting tray. So, after a quick visit to the farm to give the truck a run, I bought some aluminium sheet and bar to replace the missing mounting plate, and to make two FT-154 receiver mounts.

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I annealed the aluminium sheet along the fold line first, then clamping the sheet between two pieces of wood, folded the front lip. The rectangle was cut out next with a metal nibbler, then dressed with tin snips and a file. The holes were drilled next for the mounting pin and retaining clip.

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The tray was then drilled to match the rivet holes in the radio housing, etch primed, and when dry, sprayed with the hammer finish black. That was left to harden over Friday night, and was given a matt clear coat before fitting.

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The next job was turning the four metal spigots that locate into the mounting tray. All four were turned on one 30mm aluminium bar. Once the taper was machined, they were parted one by one, and then the four mounting holes drilled. It took 5 hours of machining to make these four pieces!

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The paint was cleaned away under where the mounting spigots were to go. In addition to the four rivets, I took the precaution of using some 24 hour Loctite Hysol 9462 epoxy.

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The mounting plate was also riveted onto the radio case, and this was also glued for additional security. While that was curing, I made a start on the retaining clips. I had wanted some bright steel strip, but couldn't get any thin enough, so ended up with stainless steel. This was very hard to work, but after drilling the holes, the slot was cut with a miniature stone cutting disc.

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The base plate for the retaining clips were made from 0.25mm aluminium sheet, and then a turned rivet was made which will hold the clip onto the mounting plate. The new clip is shown below next to the original on the first receiver.