TLJC 1/6th Hyper Scale F105D Kit

At the heart of our Hyper Scale design philosophy is the real aircraft. Scanning the actual aircraft captures every detail and allows us to reverse engineer the scan data into a useable solid model, which we can then use as a base for our kit design. There is no doubt our Hyper Scale F105D is the correct shape with scale fidelity as close to 100% as you will ever get. We can model every nuance, every panel line and be absolutely confident that we can supply our customers a true representation of the F105D Thunderchief.

Below are some images of the raw scan data captured in Florida, USA. It's also worth noting that the images you see rendered from the scan data have been done so with highly decimated data. What this means is these renders only show a fraction of the detail captured. It's not practical to render the un-decimated raw scan data even with our immense multi threaded workstation producing the equivalent to 30Ghz of processing power. The scan allows us to accurately measure every detail even down to the diameter of the rivets used in the original manufacture.
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With the scans complete and all the data cleaned we can make a start on producing a solid CAD model that can be used as the base of our design. I wish there was a button that could turn the captured scan data into a solid useable CAD model but unfortunately this is impossible, especially considering the level of accuracy required. With this in mind we needed an engineer with very particular skill set, through contacts with our scanning team we managed to secure the services of a specialist engineer who has plenty of experience doing this exact task. Carl now works for us on all our projects specialising in creating useable CAD models from raw scan data ensuring we have the most accurate model possible. I firmly believe the level of accuracy we have achieved would be impossible without scanning the original aircraft. There is no hiding the fact that this is an expensive process but the results more than make up for the increased development costs.

Below you can see a few renders of the CAD model (Yellow) in progress while overlaid with the scan data (Silver). Once scaled to our chosen size the accuracy between the scan and CAD model created is +/- 150 microns.

F105D Scan - CAD overlay 1
by Alex Jones, on Flickr
Close to 1500 hours of work have gone into getting the base CAD model as accurate as possible, including the scanning, trawling through tech manuals, photo research and historical research. What we are left with is a solid CAD model which will form the base of all our design work moving forward. Some areas are deliberately omitted or added to due to design intent for the eagle eyed among you. This base model is dimensional as close to 100% accurate as is possible.

We're excited to move onto the next phase of the design which is a real departure from the norm but will allow us to manufacture lighter, stronger and incredibly detailed scale models manufactured here in the United Kingdom.

Below are the CAD renders of the our base model F105D Thunderchief.

by Alex Jones, on Flickr

F105D Base CAD model 1
by Alex Jones, on Flickr
by Alex Jones, on Flickr
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With the base CAD model complete we can start to think about the model specifications. It's worth noting that this was a huge aircraft so the smaller scales still represent a decent sized model. The trend over the last five years or so is that models are getting larger. Fuselage lengths of over 4 meters (13 feet) are not uncommon and associated costs of turbines in excess of 30kgs really pushes up the cost of ownership considerably. With this in mind we want to create a model with presence but still be able to transport it without a van or trailer. We need it to meet the regulatory requirements for countries we believe it will be sold in so our customers don't have to spend time and expense getting the model certified by their relevant aviation authority. With this in mind we would ideally like to achieve a dry weight of between 16kg - 18kgs. This may seem light for a traditional composite built RC jet, however, we are designing our aircraft very differently with the focus on advanced composite design which will allow us to significantly reduce the weight of the standard airframe.

Fuselage Length:

1/8 = 2.45m
1/7 = 2.8m
1/6.5 = 3.0m
1/6 = 3.27m
1/5.5 = 3.56m
1/5 = 3.92m
1/4 = 4.9m

Looking at the above scales we have initially decided on 1/6th with the caveat that this scale will allow us to suitable optimise the aerodynamics. Once we have completed our CFD and wind tunnel testing we can make a final decision.

by Alex Jones, on Flickr
With the model size in mind and our hyper scale philosophy we can move onto the scale features. It would be great to hear from the community regarding what you would like to see on this model. So do get in touch either on this thread or via email.

The below list may not necessarily be developed but if we have some feedback perhaps we can focus on a few or all depending on demand. We are not counting primary flying control surfaces as features as they are obviously essential.

Starting with the wing…
  • Prototypical fowler flaps
  • Leading edge flaps
  • Spoilers
We may make some of the above as options, however, the plan (cost dependent) is to produce the prototype with all of these features on the wing until we can assess the flight characteristics.

  • Working scale pitot probe for use with telemetry
  • Retractable refuelling probe which will double as the fuel fill access
  • Working opening canopy
  • Hyper scale cockpit
  • Hyper scale pilot
  • Scale access hatches
  • M61 Vulcan Cannon
  • Brake chute
  • Working afterburner petals which double as speed brakes
  • Afterburner ring
  • Light package
The F105D was a versatile aircraft but almost exclusively deployed in Vietnam as a bomber. We want to be as accurate as possible and our initial research has shown the below loadout to be an interesting mix of ordnance.

Rolling Thunder Ordnance Package
  • Centre mounted MER (Multiple Ejector Rack)
  • Centre mounted pylon for MER
  • 4 MK117 GPB (750lbs) MER mounted
  • 2 MK117 GPB (750lbs) extended daisy cutter fuses, MER mounted
  • Wing inboard tank pylons
  • Wing fuel tank (450gal) mounted on above inboard pylons
  • Wing outboard pylons
  • AIM9B Sidewinder and rail, left wing
  • QRC-160-1/1A E band Barrage Noise Jamming pod which became the AN/ALQ-71, capable of jamming the S-25 Berkut (SA-1), SA-75MK Dvina (SA-2A/B/F), and the SON4, SON9 AAA systems.

by Alex Jones, on Flickr

by Alex Jones, on Flickr
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Alex, I like the size, but I honestly don't see how you can keep a 130" model at, or under 40 lbs (I like to use English dimensions). I appreciate the possibility that you can keep the composite part of the construction as light as possible, but you have to deal with the increase weight, due to larger operational accessories. These include; engine, tailpipe, fuel pump, fuel tanks, landing gear, retracts, powerbox (receiver), batteries, servos, wiring, lights, cockpit detail, operational canopy and speed brakes, external pylons and stores, and any associated support equipment for the aforementioned. Then, add fuel, as a minimum, another 5-6 lbs. My guess is you are looking at an all up weight in excess of 50 lbs! I hope I am wrong and I wish you well! Gary Chudzinski
Hi Gary,

I'm glad you think the size is about right, we want to make it as manageable as possible. Regarding weight... I may well be wrong and the aircraft is under development so it is only an estimate based on our design work. I'm certainly open to the idea it may weigh more and my estimated weight doesn't include pylons or ordnance. However, we are designing this model very differently to anything that has gone before. Imagine just one central composite component in the fuselage, this acts as a structural element, includes an integral fuel tank, turbine mountings, wing spars, cockpit tub and oleo mounting. One single component designed to support everything that is required in the fuselage and weighs under 2 lbs. Hopefully all will be explained as I post more but using chartered structural engineers and composite design specialists we are confident that our airframe will benefit from the best in composite design. It is a real departure from what people are used to but I really believe with the technology available to us today we can improve the way our models are constructed. Keep following and all will become clear.
Alex, I hope you don't think i'm challenging your approach....I hope you are able to keep it light as that makes a big difference in engine size, which means COST! My thinking is geared more towards the items of which there is not much latitude in weight savings. My experience has been; for good acceleration, takeoff and vertical performance, the thrust should be at, or above the empty aircraft weight. Certainly not absolute, but a good rule of thumb! I have no expertise in composite materials. But, if you can reduce the air frame weight without compromising strength of a large aircraft, more power to you! Another thought I have is, high wing loading, Perhaps your plan includes some slight wing modification for that, and the difficulty with enclosing the main landing gear (strut rotation) into the thin wing. I admire you for the challenge you face! Gary
Not at all... This is the reason we did the forum, having prospective customers or just interested parties joining in and following our development is really important.

Realistically people will install the turbine at the top end of our recommendations which will be a 220N. But as you say we really want to have this model accessible to those that own the smaller turbines. We are certainly aiming to have the dry weight under 20kg as this keeps it within the standard regulations across the board.

Wing loading is another reason for keeping the weight down and it is a challenge to fit everything into that thin wing! The wing will not have scale aerofoils for obvious reasons and will be slightly thicker but not visible so as we want to maintain the distinctive blend of the intakes into the wings as this area has lots of character on the full size.
This is a great website and I'm enjoying the detailed information you are providing with regards to the F-!05 project. I don't know if my other message made it through, but I like the interesting project you are taking on. The Convair Sea Dart and Hustler are great choices along with the Republic Thunderchief. Two others unusual fighters you may consider at some later date are F-16XL/F-16E and NA F-107A. My fighter time was in F-84F, F-100C/D/F, A-7D and F-16D. However,my true love was my first fighter, the Hun! Gary
Hi Gary,

I did respond to your email, perhaps it went into your junk folder.

The 16XL and F107 are interesting but perhaps a little out there for a product, I love the A7 and F100 but these are in production by other companies. How about an F106?
Regarding the F-16XL and F-107A, you might be correct and probably greater interest in the Delta Dart. Nice looking fighter, but as an interceptor, it carried nothing unusual externally. I only recall one kit of the F-106 by Daryl Usher, back in the nineties, but I don't think he sold many. My unit deployed several times in Schulthorpe, near Kings Lynn, in the nineties with A-7's. Loved flying low level, sight seeing over East Anglia! Interesting, was the large number of people with cameras at the end of the runway, capturing our arrival.
Hi Alex,
Really interesting project and appraoch. May have missed it but is there an approximate target release date for availability i.e. this year - first half next year et al? The size is right for me but will it be possible to split the fuselarge for transportation?
Hi Rob,

We can't commit to a release date as we have a lot of work left to do, however, the earliest possible date would be Autumn next year. The fuselage is designed to split as the full size did which leaves a 2.3 meter centre section. The vertical stabiliser is molded into the aft section and the horizontal stabilisers are easy to remove. It will be able to fit into a standard size family car.