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The sidewalls are made from wooden frames covered with thin MDF panels. For attaching these panels on the frames use (hundreds...) of flat-headed nails. Later those will look like the original rivets on the fuselage. Install the sidewalls on the bottom frame with 8mm bolts and nuts for later disassembling (if you want to move...)
Also install an open frame on the front for stability.
Use brass angles for connecting. Try to use only bolts and nuts as much as you can and try to avoid these typical self-made mans wooden screws...these are only useful if you want to remake your wooden floor in home, but not if you want to build an aircraft.
If you're making aircraft models, you shouldn't have problems in building the upper shell frame...it's just the same way. Cut from 12mm MDF three (or more) bows which cover your favorite aircraft's dimension. I also didn't have all original dimensions of the 737, but you can simply try to compare with known dimensions and photographs. Also attach these bows with bolts and nuts for removing the roof if it's necessary.
Connect the MDF bows with wooden slats.
Glue little wooden blocks as much as possible at the MDF bows. These little cuties are very important to connect the outside hull with the frame.
Than our job gets a little bit tricky...
From the same thin MDF used for the sidewalls, bend your upper layer over the bows. Try to be careful, because these plates break quickly. Here you may use wood screws! In some places the angle might be too large to bend the plates in the right position. In this case you'll cut the MDF and distribute it on different layers.
If all layers are attached and the whole thing looks like an aircraft (or what else you want to built) cut the window openings into the shell. I know...my cuttings don't reflect the original B737 window dimension...So do it better!
If you want to, you can paint your shell now in your favorite livery. The whole shell is still easily transportable if you are willing to uninstall the roof and the sidewalls. Now it's up to you to complete your flightdeck with realistic details such as described in my other tutorial or in my gallery. And don't listen to comments from friends that it looks like a truck cabin...If you think it's a real aircraft, it is a real aircraft which stands in your bedroom or where ever!
Greetings to everyone,
Daniel Friede
Dutch@dutch-mountains.com
For further information about my project have a look at www.dutch-mountains.com
