Restored Aircraft uses contemporary engineering techniques to make classic planes fly again.
Siemens has sponsored this post.
In the world of aviation, where giants like Boeing and Airbus dominate the market, there exists a niche industry dedicated to preserving the past. John Roper, a passionate aviator, has built a thriving business called Restored Aircraft in Leavenworth, Kansas, to do just that. Roper is working to accurately restore parts and even entire airplanes, allowing collectors and pilots to experience the classics of the past.
A Labor of Love
Restored Aircraft is not your typical aviation business. It’s a labor of love for Roper and those that share his deep appreciation for legacy aviation.
“My love of restoring aircraft started as a young kid building snap-together models when I was in kindergarten. When I was eleven, I started building and flying radio-controlled aircraft – I always liked adding the details that made them look as realistic as possible. I would use eyeglass screws in the instrument panel to make them more realistic.” That love of the aircraft itself and his passion for detail laid the groundwork for his background in engineering and the eventual founding of Restored Aircraft in 2018, where his fascination with vintage aircraft led him to embark on a mission to restore these magnificent machines to their former glory.
“I started this business to get into what I love the most, which was restoring old airplanes. The, the industry has changed so much over the years, and because there is a lack of support for those trying to do these restorations, I’ve been trying to find new technologies and trying to figure out how to bring some of these technologies to the guys that are restoring airplanes. So not only do I restore old airplanes, but we’re doing individual parts, and making jigs, and using more modern tools to create parts for people,” he explained.
However, the restoration business isn’t just about breathing new life into old airplanes, it’s about keeping history alive, celebrating the craftsmanship of a bygone era and ensuring that future generations can experience the magic of flight as it was in the past. Restored Aircraft isn’t just a business; it’s a bridge between generations, connecting those who dream of soaring through the skies in classic aircraft.
Roper is passing along his passion for old aircraft by teaching kids to do reverse engineering and contribute to his restoration processes. For reasons of protecting their IP, major aerospace companies don’t provide access to modeling information, etc., so he uses the restorations to help teach high school students about CAD and drawing in the real world.
A Unique Approach
What sets Restored Aircraft apart is its approach to restoration. Roper’s vision extends beyond the act of restoring old airplanes, embracing modern technologies and methodologies to make the process more efficient and accessible. He’s not just preserving history, he’s evolving it.
“Everything starts as a one-off. Right now, I’ve got two Boeing Steerman in work and the first one that came in was actually not a full restoration. It’s a bunch of modifications that we’re doing for an airshow customer, so he wants the airplane highly modified,” Roper says. “With the engineering and everything that went into that, we were able to use that insight and we’re pulling it forward into the next Steerman that we’re doing, which is a historically accurate restoration. That’s why it’s always a challenge when we decide to accept the next model of airplane; to see what’s there, what we need and how deep we want to get into it on the first one.”
The process always starts off with a basic set of engineering principles, redrawing the ribs and some of the basic components, like the fuselage, that every airplane needs. Then they turn to specific elements that may need updating and making the plane flyable.
Roper’s passion isn’t just limited to restoring entire aircraft; he and his team also manufacture individual parts, design custom jigs and leverage modern tools and technologies to create components that would have been challenging to replicate in the past. This holistic approach not only preserves the aircraft but ensures they can continue to fly safely and meet modern regulatory standards.
Targeting the True Enthusiast
Restored Aircraft’s primary clientele consists of aviation purists who seek to rebuild the aircraft as close to the original design as possible. These individuals aren’t merely looking for a functional airplane, they’re looking to recreate all the aesthetics of the original craft—a plane that can turn heads at airshows and evoke a sense of nostalgia.
Moreover, this dedication to excellence enables Roper to further research, engineering and tool development, allowing him to assist other enthusiasts. Whether it’s providing drawings, manufacturing parts or offering consultation, Restored Aircraft’s reach extends beyond their core clientele to benefit the broader aviation enthusiast community.
Some of the planes that Roper works on are able to fly in, while some are what Roper called “barn finds.”
“Sometimes, it’s a pile of sticks that’s been sitting in a barn for 30 years and we’ve got to start from scratch. So, there’s always that process to figure out exactly what the customer has and what it is going to take to figure out how far we want to carry it,” he explains.
From Scanning to Solid Edge: Modernizing Restoration
A pivotal aspect of Restored Aircraft’s unique approach is its integration of modern technology, notably CAD from Solid Edge. This software plays a vital role in bringing these vintage aircraft back to life while incorporating modern upgrades and safety features.
When looking at a model in Solid Edge, Roper explains, “I could use the model of that wooden rib to machine out a rib jig. Then, that gives me the tool that I need to start building up a bunch of parts and replace some or all of the ribs on a plane we’re working on.”
Three-dimensional scanning is a crucial part of this process. Using 3D scanning technology, Roper and his team capture intricate details of the aircraft components that have undergone years of wear and tear. This scanned data serves as the foundation for creating new, precise models, ensuring that every replacement part is a match to the original.
“We don’t really have good drawings for every little contour and there’s a lot of compound contours on these parts. We don’t have access to the original tooling, either. So, we 3D scan and instead of trying to fabricate something out on the shop floor, we can actually design in such a way that we’re doing all of our repairs digitally. Then I have my final part that I can send off to the machine shop and have that CNC machined out of aluminum or 3D printed for test fitting.”
Through Roper’s CAD workflow and 3D scanning, Solid Edge helps Restored Aircraft optimize the restoration process. They can design and manufacture jigs, recreate wooden ribs for wings and even simulate the impact of various forces on their designs. This digital approach not only expedites the restoration process but also enhances safety and ensures compliance with modern aviation standards.
Bringing vintage aircraft up to contemporary standards for flight is particularly important for clients who wish to use their vintage planes for airshows or other events. For example, Roper can incorporate glass cockpit instruments, modern avionics and electrical systems into these classic aircraft.
“One of the issues that we’re running into is the same as the automotive industry… we can restore it to exactly what it was in 1937, but you won’t be legal to fly. So, we need to figure out how to do that mod where we’re using a more current injection system or more reliable ignition system, putting in the fancy glass panel instruments, things like that. And figuring out ways to hide them a little bit better, so that you can preserve the original feel of the airplane while being legal to fly into Oshkosh,” Roper says.
This transformation isn’t just about meeting regulatory standards; it’s about preserving the aircraft’s original charm. Using Solid Edge combined with existing models and scanned assets, Restored Aircraft works to seamlessly integrate modern upgrades into vintage designs, creating a harmonious blend of traditional aesthetics and modern technology.
“We’re using Solid Edge for a lot of the structure, but we’re just starting to use it to get more into avionics, upgrades and even wire and harness design,” Roper explains.
Preserving the Legacy
In a rapidly changing world, where vintage aircraft become increasingly rare with each passing year, John Roper and Restored Aircraft are on a mission to preserve the legacy of aviation. Their work ensures that future generations can experience the thrill of flying in these iconic machines and appreciate the craftsmanship and history behind them.
The story of Restored Aircraft isn’t just about restoring airplanes, it’s a testament to the power of passion, technology and dedication. Roper and his team are writing a new chapter in aviation history that brings the nostalgia of the past into the contemporary age. As long as there are vintage aircraft in need of a second chance, whether they are flying rust buckets or a pile of sticks in an old barn, Restored Aircraft seems to be ready to restore them to their former glory.
Educating Young Aviators
When Roper is not actively restoring vintage aircraft, he is busy teaching others how to do so. Roper’s is happy to share his knowledge with the youth. You will find Roper and his team at EAA’s AirVenture in Oshkosh, Wisconsin each summer and at the Aerospace Center for Excellence SUN ‘n FUN Expo in Lakeland, Florida every spring, events that provide hands-on education to tens of thousands of kids each year.
“How do you get kids energized about technology? Make them part of the process,” says Roper. “We had these kids use Solid Edge to re-design a piece of an airplane rib and put that part into the 3D model of the whole structure. Then, we 3D printed it as a small chip so the kids could take it home. It serves as a reminder that they designed a real part of a real aircraft and takes out the mystery and intimidation of technology.”
About EAA
The Experimental Aircraft Association (EAA) is an international organization dedicated to promoting and preserving the spirit of aviation. It brings together aviation enthusiasts, including those interested in building and flying homebuilt and experimental aircraft. EAA is known for hosting renowned aviation events like EAA AirVenture Oshkosh, advocating for favorable aviation policies, providing educational resources and fostering a sense of community among aviation enthusiasts and pilots. EAA plays a significant role in supporting aviation and encouraging individuals to explore and engage in various aspects of flight.
Siemens Digital Industries Software and EAA have joined forces to promote youth engagement and education in the aviation industry through the EAA AeroEducate initiative. Siemens Digital Industries Software serves as the official technology partner for EAA’s aviation and aerospace education. The collaboration aims to provide young people with an interactive and educational experience that sparks their interest and enthusiasm for aviation. Part of the collaboration is also free access to 3D CAD software tools and training for EAA members.
For more information on Siemens Digital Industries Software and EAA, visit EAA.org.
To learn more about Solid Edge, visit Siemens.
