News on the Do X reconstruction project

News on the Do X reconstruction project
News on the Do X reconstruction project

Here you will find current reports on the status of the project. Information on our public relations work and other news.

————————— The foundation stone for Do X is ready —————————

The first component for the replica of the Dornier Do X airship is ready. It took a good 8 years to produce the first component from nothing, as there were no more detailed design plans. The reconstruction of the Do X began in 2014. Since then, a total of 112 students from the Cooperative State Universities in Friedrichshafen, Mosbach and Lörrach have worked on the Do X project, putting in 33600 hours.

In the three phases, strak creation, pre-construction and detailed construction, construction plans were created again from a few general drawings and pictures from the construction phase of the airship. These blueprints are as accurate as possible to allow an original replica of the Do X.

The now completed rib 44 underlines this originality and the claim of the Freundes- und Förderkreis Do X e.V. to rebuild the legendary flying ship Do X as true to the original as possible. The component corresponds 99% to the original rib of the Do X. Deviations are only caused by inaccuracies in the measurement of the used general arrangement drawing or pictures. And the rib proves impressively that a reconstruction of the Do X is no longer impossible.

The rib 44 was built by Ali Storiche 57, a company that already built the Dornier Wal and the Dornier Merkur aircraft.

The used general drawings and pictures from the
construction phase of the Do X would be kindly provided to the association by
the State Archives St. Gallen.

Do X Rib 44 with the Ali Storiche 57 Building Team

————————— The building phase of rib 44 from September to November 2021 —————————

The first component for the replica of the Do X will be the fuselage frame 44. This gigantic component, measuring 6 x 4.60 m, is the cornerstone for the replica of the legendary Do X.

In addition to the pure presentation of the component, the rib is intended to prove that a replica of the Do X is possible in principle and true to the original. The first rib produced underlines this originality and the claim of the Freundes- und Förderkreis Do X e.V. to rebuild the legendary flying ship Do X as true to the original as possible.

Rib 44 with Michael Schliep, the lead of the construction, to illustrate the size of the component

Rib 44 was ordered in August 2021 and will be built in Hereg, Hungary, by Ali Storiche 57 kft. This company has also already produced the Wal aircraft and the Merkur aircraft for the Dornier Museum in Friedrichshafen.

Before building Do X ribs, a new integration table had to be built for assembling the components due to the dimensions of the ribs. The table has the dimensions of the largest Do X rib (6.5 x 5 m) and is constructed from two partial tables.

The subcomponents (profiles) are largely manufactured by hand. As these are individual items and not series production, machine production of special profiles, for example by rolling, would be uneconomical.

Various types of profile, such as U-profiles, U-profiles with board, L-profiles, T-profiles, square profiles and A-profiles, are required for the production of frames. In the case of A-profiles, a distinction is made between normal A-profiles and A-profiles with adjustment to the shape of the fuselage.

The production of A-sections proceeds as follows. First, an approximately 150 cm long steel master mold is made for the outer rounding of the A-section. This master mold is placed in a press. A cut-to-size strip of aluminum is first placed on this master mold, followed by a steel tube for the inner rounding of the A-section. Then the press is used to press the steel tube into the master mold by means of a wooden board, thereby shaping the aluminum. Next, the shaped aluminum is clamped in vices and the two tabs are chamfered by hammer blows. To finish, the A-profile is straightened if necessary. If longer profiles such as the parts produced in this way are required, then several elements of the A-profile are riveted together.

Production of A-Profile outer rounding

A-Profil outer rounding

Mark of the Straps

Production of the straps

Justify the Profile

The finished A-Profile

U-profiles and U-profiles with board are produced on the bending bench. For a U-profile, the prepared aluminum strip is bent twice on the long sides in the bending machine. For a U-profile with a board, the folded sheet is folded again on the long sides.

First bending

U-Profil

Second bending

The finished U-Profile with board

L-profiles are also produced in the bending bench. T-profiles are made from two L-profiles. Square profiles are parts that are purchased.

And here are some pictures from the Rib 44 production

Riveting of the profiles

Left side of Rib 44

Right side of Rib 44

Detail of Rib 44

Detail of Rib 44

Half of Rib 44

————————— Successful completion of the 7th year of the Do X reconstruction in July 2021. —————————

Currently, 41 students from the Cooperative State Universities in Mosbach, Lörrach and Friedrichshafen are working on the detailed reconstruction of the Do X. Within the scope of this effort, the construction of the Do X fuselage will be nearly completed by July 2021.

At the end of this effort, a total of 112 students will have worked on the project, putting in 33600 hours.

The result of the work at the Jour Fix in February 2021 is shown in the following pictures. The Do X is composed of detailed construction (green elements), pre-construction (gray elements) and strak (outer skin).