A201’s Restoration

My company, Blue Swallow Aircraft, LLC acquired the last unrestored Avro 504 project in the World in November of 2011. Here are pictures of the plane as it is being restored.

A201’s fuselage in March 2016. The undercarriage is completed and put away as well as all 110 wing ribs and much of the interior fittings.
Avro 504K controls
Machining steps for Avro 504 A201’s aileron pulleys. May 2021.
Avro 504K Aileron control pulley
Central aileron control pulley finished and awaiting installation in A201’s fuselage.
Avro 504K seat rails
One of two seats and the seat rails waiting to be installed.
Avro 504 landing gear
Avro 504 A201’s undercarriage being fitted.
Avro 504K undercarriage
The iconic Avro 504 ski designed to reduce student pilots from nosing the plane over and damaging their machine.
New Avro 504 fuselage fittings
Avro 504 parts awaiting installation. Photo by Hugh Martin
Avro 504K drawings
Original Avro 504 drawing. Photo by Hugh Martin
Completed spruce and plywood “stations ” for the top of the Avro 504 A201’s fuselage
Photo by Hugh Martin
Avro 504 A201’s elevators and horizontal stabilizers all finished.
The iconic “comma” rudder so characteristic of all variants of the Avro 504 built between 1913 and 1920’s.
Casting pattern on the left and finished cast Avro 504 axle covers made by Blue Swallow Aircraft, LLC.
3D printed pattern Avro 504 rudder bar castings
Original drawing of the Avro 504’s rudder bar foot rest and 3D printed casting pattern.
Blue Swallow Aircraft's Avro 504 rudder bar castings
One of the finished rudder bar foot rests awaiting installation.
Avro 504 fuselage fittings
Just a few of the many parts that had to be made to assemble the Avro 504 A201’s fusealge. Many of the original parts that came with the project were used as patterns if they were considered non-airworthy.
Avro 504 wing ribs ready for installation
110 wing ribs in the four main plane panels for the 504’s wings.
Blue Swallow Aircraft made Smiths & Sons Inclinometer
Blue Swallow Aircraft made Smiths & Sons British WWI inclinometers for the Avro 504 cockpits.
Solidwork drawings of Avro 504 parts
Just a tiny smattering of the hundreds of SolidWorks drawings created for the Avro 504 project.
Avro 504 seat rail supports
Seat cross braces with 3D printed samples and 3D printed brackets for Foot Boards.
Avro 504 Seat Rail brackets
Foot Board Front Brackets made for 16G MS. formed with dies and hydraulic press.
Avro 504 metal parts
Press work for forming foot board supports. 1600-2000 PSI per 12″ of material required for 16G MS.

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