posted 08-18- 05:01 PM               

The history of Flug Werk GmbH

It is every pilots dream to be able to fly a fighter aircraft.

We would love to (safely) join in those aerial jousts of a by-gone era when men and machines relied less on electronic gadgetry and more on skill and nerve to down an "enemy" fighter.

To be one of the select few who have the opportunity to fly in the aging fleet of restored warbirds in museums and private collections is a rare privilege. To be able to afford to own one is only achievable for those even rarer individuals with the discretionary funds to be able to do so. As time goes on, the remaining warbird population is getting older, insurance premiums rising and those permitted to fly them becoming more restricted.

The Kit Builders market has attempted to address the desire of many pilots who want to own a Warbird at an affordable price. The proliferation of reduced scale replica kits has blossomed and filled many a garage with a lifelong hobby. The purists may frown at the attempts of those who try to fulfill their champagne dreams on a beer budget, however, it satisfies a creative need and keeps interest in aviation history alive and the industry going.

Some fifteen years ago, a German airline captain, Claus Colling started constructing his own replica scale Mustang and, given his connections and background in engineering, he also began to build reduced scale and full scale warbird replica parts for kit builders and restorers all around the world.

There seemed to be a growing demand for German aircraft replica parts and discussions with colleagues and friends indicated a strong interest in full scale German fighters from WW2. As there were so few originals surviving it became apparent that if one was interested in a full scale replica it would need to be based on some plans built design using steel/composite or wood/steel/composite construction techniques.

Claus and his friends dabbled in building composite replica's but the real interest seemed to be coming from people who wanted the "real thing", not an "ersatz" copy. It also started to become apparent that if such a project were possible the money was there to pay for it.

The problem, of course, lay in building an all-metal fighter from the ground-up with no jigs, plans or infrastructure for such a project. There were so few examples of German warbirds from the tens of thousands built during the years 1939/45 yet, interest in and out of Germany was strong. There had to be a way to satisfy the potential market for such aircraft. For several years this idea simmered as a compelling dream with Claus and the dream began to become an obsession.

Whilst nurturing his ideas and developing his growing business in replica components, Claus committed himself to a CM170 twin jet Fouga Magister rebuild. The Fouga was the first Luftwaffe aircraft in German production after the war and the restoration was completed in 1994 and became the first back on the German registry since they were phased out of service in the late 60's. The rebuild of the Fouga had introduced Claus to specialist East European aircraft builders and parts manufacturers who had the expertise he was looking for in a replica project. Claus's commitment to German aviation also earned him the respect and friendship of many people who
were actively involved in aircraft restoration and history.

Claus discussed his ideas for a full scale all-metal reconstruction with sympathetic associates and, in a short time, doors began to open, technical assistance, access to original plans, components, moulds all began to appear. The parts necessary to fulfill his dream were beginning to fall into place.

Claus asked his friend, Hans-G. Wildmoser, a mechanical engineer with a keen interest in aircraft to work with him in developing a program for a complete re-build of a German WW2 fighter plane and Hans readily agreed.

The first aircraft of choice in the rebuild program was an FW190A. The reason for this choice was the ground work already completed in component sub-assemblies for other FW projects and access to a nearly full set of original plans (over 5000 sheets).

The support for the FW190 project was so strong that the German industry agreed to issue a block of works registration numbers from the original production facilities abandoned in 1945. Suddenly, the project was no longer a "replica" construction but had become a continuation of the production series from 1945 ! Whilst there are some minor changes to the plans, for example, the substitution of aluminium plate for amour plate, it is arguably an "original" aircraft.

As the project gathered momentum, original parts also began to emerge from many different sources, instruments, canopy moulds, wheels and brakes etc. The use of the ASH radial motor (built in the former USSR) closely approximates the BMW engine in power output and technical aspects and permits the use of a contemporary motor which is almost identical to the original.

In 1995 Hans & Claus put together a business plan and arranged the financing of an initial production run of 12 FW190 fighters. They registered the name Flug Werk GmbH (Focke Wulf is still a registered proprietary name in Germany) so that aircraft could be registered with the "FW" designation. The German civil aviation authority has allowed continuation of use of production numbers with the addition of the "N" designator which denotes "Nachbau", meaning "remake".

Hans converted original plans to a CAD system and transferred these to component builders in various factories in East European countries. Jigs and moulds were built under close supervision by Flug Werk and during 1997/98 various components and sub-components began to emerge and were shipped to their German aircraft engineering facility for final assembly.

In late 1997. the first complete prototype fuselage and wing assembly were tested for fit and alignment such that final assembly jigs could be produc d. This prototype was sent to an air museum near Hannover for static display in 1998.

In December of 1998, a complete, mated fuselage and wing assembly were rolled out on the jig.

The project is now in the final stages of completion. Of the 12 aircraft on the assembly line 9 have been sold, as of mid-`99. The German government has given permission for the first 3 aircraft to be built in Germany to be registered under their tough aviation certification requirements.

And the cost of an FW190 aircraft kit ? The kit cost is about US$520,000 ex-works Germany. Build costs will vary from country to country.

Other aircraft are being shipped in complete form to European countries and in kit form to the U.S. where Flug Werk GmbH has set up a sales and service company called Flug Werk of America Inc. in Chandler, Arizona. Flug Werk of America will sell kitsand parts in North America as well as providing jig services for kit builders.

Claus is also seeking a representative organisation to be based in Australia to look after the South East Asian and Pacific Basin.

What's in store for the future at Flug Werk ? Flug Werk is expanding the components list for ME109 parts which they fabricate and sell, as well as other "Allied" aircraft parts for Spit's and Mustangs. There is a list of WW2 German fighter projects on the drawing board for future construction including ME109, HE112 and Ar96.

Given their knowledge of the industry, expertise and facilities at their disposal, Claus and Hans can offer a comprehensive service for restorers and builders of all types of vintage aircraft.

When asked how it was possible to realise his dream, Claus replied, "Nothing is impossible. If you believe in yourself others will too. Once they see that you can do what you say you will do, then they want to follow; to share in that success, and nothing breeds success like success."