Hi all,
At the risk of overloading on Lightning threads:o, In response to requests by forum members to set up a thread on the history and progress of Project53 E E Lightning ZF579 rise from the ashes, here it is. Most of the history has been documented at http://www.gatwick-aviation-museum.c…g/mainsite.htm, under the progress and news section, its too exhaustive to even attempt to post all of the history on the rebuild here, especially at the advanced stage it’s at now. However, some pictures here will give the gist. Like all of the other Lightning groups in the UK, bear in mind it’s a weekend thing only.
ZF579 is an ex Saudi Air Force Lightning, returned to Bae Warton in 1987, along with another 12-13 mint low hour examples. For various reasons, all, including 579 sat and festered for 4 years outside in the estuarine Warton air, being reduced to little more than scrap really. In 1990 579 was taken apart and put into a sea container for sale to a private collector. She then disappeared for 7 years ( sat in her damp container at Southampton docks with the other 12 airframes) before re-appearing at Marine Salvage scrap yard Portsmouth in 1997. She then disappeared again to Luxembourg for the filming of “Wing Commander” until her return to UK in 1999. In early 2000 the bare airframe, spares, new engines, and most of the components required to overhaul 579 were purchased for Gatwick Aviation Museum, much of it in triplicate.
April 2000 saw the arrival of a very sorry looking empty airframe, sporting various scars from her journeys too. The basic airframe was bolted back together by June 2000, and then put on the back burner until March 2001, where a full survey revealed that with 8-9 years work, she could be completely re-build and overhauled to ground run. The team initially consisted of 2-3 blokes for 12-15 each hours a week, and continued this way for 4 years. Then the team grew to 4, and now stands at 5 regular guys, every Saturday, for a combined 30-40 man hours a week. Unfortunately, even though the plan was simply for ground running, due to the Lightning’s complexity, and all of it’s associated systems having suffered so badly whilst at Warton and the docks, and being sat for 15+ years, every facet of her would require overhauling. As the 2000 + items came out of their storage stillages, it quickly became evident that the project was going to be a one off, v unlikely to be repeated again, and with some huge challenges ahead. Anyway to cut the waffle, 8 years down the line and 7500 man hours later, we arrive at today 90% the way there. A few pictures to give the gist, but the only way to get up to speed is to read the web site, its not a plug for the site, but simply the only way to catch up.
so here we go with some photos
first 2 shots of 579 (then 53-671 with 2 squadron RSAF circa 1970)
as ZF579 in Feb 1986 at Warton aerodrome, Outside storage
next again at Warton 1987, a year outside
next, circa 1990, and the gradually worsening state is by now obvious
The next shots are taken in 1997 and 1999, at Marine salvage scrap yard.
1997 579’s nose section
again 1997, sat next to ZF582 (which ended up, oddly enough, mostly at gam some years later, with 582;s nose going to a private owner in Reading)
this one was taken in1999 at the yard. clear to see the state she was in by now.
Next set of photos are of 579 a year later arriving at GAM in April 2000
April2000 579 is unloaded, along with all her components, ancillaries and spares. At this point the gravity of what we are taking on sinks in!
A month later and her bare shell is back together
You can see what a state she was in, including most of her missing
wiring!
A year later March 2001, and the work begins, opening 579 up
to take stock of the damage.
One of the first jobs was to open up the gear bays. This is what she
presented us with. Heartbreaking to say the least!
thanks to wing commander film crew 579 came back to us minus its
wiring looms on the nose. add another 2 years to the rebuild!!
circa 2002 a completely knackered port wing fuel system..
2002, and an equally knackered Air turbine gearbox.
This pretty mucg sums up the condition of what everything
looked like in the rear fuselage and gear bays
So the from 2001 to 2005 we pretty much spent the
entire time pulling absolutely everything out of the airframe,
and either throwing it in the bin, or pulling it to pieces
to overhaul it………..
This is where the work then started. here a shot of the frist
gear bay and legs being taken apart to start again..
the same gear bay a few months later, with
refurbished components and overhauled jacks/valves
[IMG]
By: mjr - 31st March 2025 at 13:34
Hi AMB. thanks for the kind words. We try our best. Dont worry, she won’t be sold to South Africa, they certainly wont be looking for another. colour scheme, she will have to sport RSAF one side and RAF the other, to keep everyone happy:-). The Warton scheme is very inobtrusive anyway, just a couple of small RAF roundels, a serial number and that’s it, so it wont detract from her clean service look.
By: AMB - 31st March 2025 at 13:34
I have to take my hat off to you and your team MJR, for your sheer skill, dedication and enthusiasm, not to mention labour of love for this aircraft.
Just don’t sell it to South Africa! 😉
I hope we will eventually see her in the only colours she ever wore operationally, Royal Saudi Air Force?
By: mjr - 31st March 2025 at 13:34
Hi all, just a smal update. It has been quiet, but we are still beavering away in the back ground, slowly.
We have been busy overhauling the last of the reheat pipes, and overhauling the IPN starters for the engine. This involves splitting the starters down, inspecting the rotors/diffuser plates, cleaning them up and testing the atomisers on an atomiser test rig.
Below is a picture from Saturday. Our shiny new No1 Avon, with starter blanking plate fitted, then after a few hours work, with nice overhauled Plessey starter fitted. next to go on the engine will be the fuledrauic pump. The Brown paper, which appears to be stuffed in the compressor, is anti corrosion paper. Electrical rewiring will get under way in April, when 579’s crew get back from Stennis Mississippi, the Boscombe tub will divert us for a month or so. Without giving too much away. It looks like 579 could well end up under cover for good in the next 18-20 months or so. fingers crossed for her.
By: mjr - 31st March 2025 at 13:34
Hi Peter, If and when she does go under cover, she will still be run regularly. ADvonge09, sorry that one has gone over my head, Im not sure I understand wat you are talking about? Lighty, thank you, we will hold you to that ha ha ha.
By: lighty - 31st March 2025 at 13:34
Well Done All
I applaued you and the rest of the team for what is a fantastic job, she’s gorgeous 🙂
I only wish I lived closer so I could help out myself (sweeping up and making tea is about my limit though) 😀
Can’t wait to see her in the flesh.
ps if I ever win the lottery I’ll pay to get her back in the air 😉
By: ADvonge09 - 31st March 2025 at 13:34
EE Lightning F53 ZF579
Thats a nice truck…but I dont beleive thats the lightning they are talking about….I think some spy pics may show up soon..heres to hoping…lol
By: Peter - 31st March 2025 at 13:34
Thanks for the update MJR! If she goes under cover will she still be runnable?
By: Arabella-Cox - 31st March 2025 at 13:32
[QUOTE=mjr;1522647] Dont worry, she won’t be sold to South Africa, they certainly wont be looking for another. colour scheme, she will have to sport RSAF one side and RAF the other, to keep everyone happy:-). QUOTE]
Hi
Fantastic work going on here – really have to admire your dedication.
Your comment about SA operations – why do you say that they ‘certainly won’t be looking for another’ (after the sad crash of ‘451)?
Cheers
Nick
By: peppermint_jam - 31st March 2025 at 13:32
Milt.
Good to see you’re still making progress on the old girl mate, more pics when you get the chance! When do you hope to drop the first donk into place?
By: Peter - 31st March 2025 at 13:32
MJR, well that is fantastic news then! All your hard efforts in repairing restoring her will not be in vain if she is to stay tucked up nice and warm in a hangar when not being ground run! Excellent!
By: mjr - 31st March 2025 at 13:32
early days yet peter, but outlook is promising. Hi PJ. I’ll try get some more pics soon and post them up. As for first Donk, not sure, certainly not until the weather gets a lot warmer and drier. Thanks Nick B, its been a long road. Re TS, I don’t want to get into a debate, but suffice to say, they won’t be looking for a replacement airframe, since they still have another 3 to keep serviceable, and spares are dwindling.
By: Arabella-Cox - 31st March 2025 at 13:31
mjr – I understand re. SA.
How is your lovely Gannet 3? Any chance of that ever ‘turning & burning’ again or is it too far gone?
Cheers,
Nick
By: mjr - 31st March 2025 at 13:30
we won’t ever do anything run wise with the Gannet, it certainly has potential to be returned from the dead, if the spares are still available. personally i have never laid a finger on it, its just too dammed ugly:D
ps your bolter quite. Is that from sailor ,when an S2 Bucc Bolted 6-7 times in a row??
By: Arabella-Cox - 31st March 2025 at 13:29
mjr – how can you call your Gannet ugly????!!! I just hope it’s not within earshot of you writing that! 😉
Would love to see a Gannet whining across the sky again – a unique sight & sound!
RE. my quote – yes it is from ‘Sailor’ when Al Gibson bolted time and time again. I received an e-mail from him (indirectly) after asking him what the real debrief from OC 809 was like after the BBC cameras stopped rolling!!!
By: mjr - 31st March 2025 at 13:24
lol, apparently the OC ripped him a new ahole, bit like the Top Gun rollockin after they do the tower fly past!! ” I want some butts, and I want them now!!!!!” :diablo:
By: Arabella-Cox - 31st March 2025 at 13:22
Yes, I don’t think Keith S-J was too happy!!
All a long time ago now- 34 years ago next month 😮
By: mjr - 31st March 2025 at 12:49
not a huge amount to report from this weekends activities. we continued to prepare n01 engine for fitting. The days focus was to fit the engine driven fueldraulic pump, pipework, and main air connections to the engine. The fuel pump fitment is an absolute pig of a job, but we got there after a few hours of cussing. We also tested the IPN starter ignition system, and it passed with flying colours. We did however find an unexpceted nasty with the oil sump, which means we are now looking for some avon 302c oil pan parts to rectify the problem. The engine itself is fortunately not affected, but it is an unexpected inconvenience.
By: Arabella-Cox - 31st March 2025 at 12:49
Looking good mate.Nice to see the engine getting all dressed up ready for fitment.
Will have to come see this in the flesh soon .
Cant wait to hear the wee-put and see some nice hot streaks from her .
The suspense is killing me lol 🙂
By: mjr - 31st March 2025 at 12:48
if there are any weeee-phutt scenarious, we will be most miffed after all the testing:D.. we just want weeeeeeee……..phhhhhhhhhssssssssssssssttttttttt instead.;)
By: mjr - 31st March 2025 at 12:47
put it this way. If you ever witness our crew working on her, you will never hear such profanity, expletives and general colourful abuse going on. We DONT have a swear jar, we tried that and no one had any money in their pockets after about 2 hours!!!:rolleyes:
The last open day we had, we forgot that the general public were around watching us, whilst 4 grown men were engrossed on a pig of an engine FCU change, in record time. A young lad sat with his dad, asked “dad? what did that man working on the plane mean, when he heard *!!@*!ing piece of *!!!t, *****!!*le British krap!!!!*, arghhh, just go in the efin hole for gauds sake!!!”
his dad wrily grinned at the boy, and said “when your grown up you will understand” we were utterly oblivious that anyone was hearing this going on. One chap came up afterward and said “thank you so much, it takes me back to when I was a linney on these things, brilliant! He’d been in stitches watching and listening to this tirade against an inanimate ogject going on :rolleyes:
sometimes I wonder why we torture ourselves…
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November 10, 2008 at 12:21 am