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Reverse Engineering Beagle Pup Prototype

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About the Project

G-AVDF first flew in April 1967 and became the first of 176 aircraft built. The beagle pup was designed as a single-engine all-metal two-seat aerobatic aircraft or as a four-seat touring aircraft. The aircraft had been in storage for many years, and the plan was for it to be restored to flying condition by the 50th Anniversary of the aircraft in April 2017.

The PES Performance team were asked by ATSO Engineering Ltd to provide a digital archive of the aircraft’s fuselage and wings ahead of its restoration.

The Challenge

As the project continued, the owner David Collings decided to source a donor aircraft to provide spare parts but whilst some parts were a straight fit, it soon became clear when attempting to use some production donor parts, how very different the prototype was. Holes were in different places and screws different sizes, strakes were a different shape and so it went on.

With no access to the relevant original plans, the PES Performance team worked with ATSO to see if the spars could be reverse engineered to the required size and shape. PES Scanning were able to use 3D optical scanning to provide ATSO with a full record of the aircraft’s exact measurements.

PES Performance design engineers used the data obtained by PES Scanning to reverse engineer the wing spars for the Beagle Pup. The team were able to deliver 2D manufacturing drawings for LAA approval. Once the drawings were approved, test parts were manufactured by PES, and a first fitting was made. Final spars were then custom manufactured by the PES Performance team – just for DF.