ACCA nuts and bolts are appearing in
LM Aeronautics Star 1Q 2008 - Volume 9, No.1
A model job: A day in the life of the Wind Tunnel Model Shop employees
By Rosie Rodela
Hundreds of Palmdale employees walk by the outskirts of Building 601 every day. Along the south
side of the building is a sign that reads: Wind Tunnel Model Shop. Although it is a large sign, very few
people know what goes on behind the closed doors of the model shop.
In a small work area, six men spend
their days creating intricate wind tunnel
models. This important job requires
great skill, attention to detail and a lot of
patience. I had the opportunity to talk to
one of the senior model specialists, Jim
Stout, who gave me some insight into
the world of model making.
Stout began his 29-year career at the
company’s Rye Canyon facility in Santa
Clarita, Calif., as a tooling helper in the
machine shop and, within three months,
was transferred to the model shop and
has enjoyed it ever since.
Model-making techniques of today
are quite different from the techniques
used decades ago. “When I first started in
the model shop in 1979, we made
F-117 models out of mahogany wood.
Each piece was handcrafted. Back then
making a model would take anywhere
from six months to a year to build. Today,
parts are “grown” in stereolithography
machines at our Rye Canyon facility.
Basically, a laser cures a polymer solution
to form contours and other components
that are attached to a metallic inner
structure and do not need to be manually
or machine cut, just handworked to fit.
A model can be put together in two to
four months.”
The model shop produces a variety
of wind tunnel models including inlet
models, exhaust models, high- and
low-speed force models and program
models. They have also made missile
models including a full-scale working
model of a Joint Air-to-Surface
Standoff Missile (JASSM).
The latest model Stout and his coworkers
have worked on is a low speed
wind tunnel model for the Advanced
Cargo Composite Aircraft (ACCA). It
has taken the team three months to build.
Stout has been doing most of the metal
handwork on the model. This includes the
aluminum wing surfaces and the fixed tail
work. Now that the team has completed
the model, they will take it apart and ship
it to Marietta where it will undergo wind
tunnel testing.
But the model maker’s job continues
even after the model is complete. A
model specialist will accompany the
article wherever it undergoes testing.
“I’ve been to England to test the F-35
model we created,” said Stout. “I’ve
also had the opportunity to travel across
the country to places such as Georgia,
Tennessee, Alabama, Virginia, Michigan
and a few other states.”
During the various wind tunnel
tests, the model maker must incorporate
all modifications to the model as it
undergoes testing. He will manually
change the flaps, work different
configurations and make any
necessary repairs.
Following the first round of wind
tunnel testing, the model is returned to
the model shop for any necessary fixes. It
then goes back to the wind tunnel
for additional testing. Once the testing is
completed and the model is good to
go, an actual prototype of the aircraft
will be built.
“It’s an interesting job,” said Stout.
“We are always doing something
different. Over the years, I’ve had the
opportunity to work on a lot of models
including the P-3, L-1011, U-2, SR-71,
various helicopters, the F-22 and the
F-35. One of the best parts about it is that
we work on something for months and
actually get to see the finished product.”
Ironically, Stout’s hobbies do not
include building airplane models.
“I like working on my cars.” ★
