A Restoration of a 1982 Era Revell Hawker Hurricane

[Brigbeale]

With the Fairey Gannet now finished and residing in the display cabinet along with the rest of the FAA family, it’s time to start a new project.

I did the usual ‘Uhmming and Aahiing’ on what to do next, but this time it had to be a Hawker Hurricane - but which one?

A new build of one of a two Airfix Aldi specials (both the same kit)? another Airfix new Mk1 kit? A NovoHurricane? Or one of many restorations.

 

In the end, I settled on a restoration of a Hurricane which was bought off EBay along with a Spitfire for about 99p if I remember correctly. 
It was painted green on top and blue underneath with all of the parts present for a wheels-up model with the exception of one propeller blade missing.

A reasonable job was done of being built, but no decals were applied.

On the underside is a marking revealing it as a Revell kit from around 1982 - so it’s 40 years old!

 

I found a set of instructions on Scalemates (actually dated later but the same kit), and printed them out. They’re correct with the build of the parts.

 

I started the disassembly by using a sharp blade pushed into some evident gaps and gently prising the parts from each other. The wing section came apart from the fuselage almost too easily.
The canopy came off just as easily. 
The fuselage separated quite well until I got to the tail-fin. The rearmost section near the trim tab broke away from the starboard side as it decided it wanted to stay on the port side instead. Also a small section on the top of the fin did the same, but it’s small and interferes with the two halves going back together, so I might sand that off and fill it one the rebuild has commenced.

The upper and lower wings started to separate along the seam but I could not get the tips to play ball, so rather than damage them, I decide to leave them.

The plan was to fit wheel well detail using the 3D printer again and also the insides of the underbelly radiator.

 

For a subject aircraft, I decided I could use a set of Mk1 decals from my Airfix MkI/IIB (from which, I intend to build a IID (the one with the anti tank guns under the wings)), P3069 RF*C from No 303 Polish Squadron from 1940.

 

Anyway, enough waffle for now - some pictures instead.

Edited April 4, 2022 by Brigbeale

[Brigbeale]

The disassembled Hurricane was placed in the usual Dettol bath to remove the paint. 
A quick check after an hour or so and it appeared to be beginning to take effect, so it was left overnight to carry on with its work.

When I was checked the next morning, the paint seemed all fully wrinkled and ready to remove.

An old toothbrush removed the paint to reveal a grey painted surface underneath the top paint. 
A telltale sign on the inside of the cockpit showed it was sprayed on, so the Hurricane was returned to the Dettol bath to see if it would remove the paint or primer.

Another check in the afternoon showed no difference whatsoever, so the Hurricane was removed from the bath and cleaned up with soapy water, rinsed and left to dry on a sunny (Yes - sunny) window-sill.

 

During my actual modelling session, I tried some airbrush cleaner to remove the grey paint/primer. Again - no effect. 
As I wanted to remove the raised rivet detail anyway, I decided to simply sand the rivets off thus removing the grey paint - which it did mostly. I didn’t want to damage the ribbed detail in the rear ‘fabric’ areas of the fuselage, so the grey has been mostly left alone. 
The kit actually has recessed panel lines and they are quite sharp and not oversized for the scale, which is a bonus considering the age of the original kit.

 

The sanding left my fingers a bit sore but it had to be done.

I have a plan for the insertion of the wheel well detail but more on that later.

 

A couple of photos of a before and after of the sanding removing the raised rivet detail on the forward fuselage and wings, leaving some grey paint/primer in some awkward places.

[ModelingEdmontonian]

Super cool project, I'll follow if I may!

[Brigbeale]

I decided to take a drastic step and remove the centre section of the lower wing assembly to enable me to measure the depth of the internal gap between the lower and upper halves. What could possibly go wrong?

This will also enable me to fit the to-be 3D printed wheel-bay in the wing assembly easier.

I found a lot of Dettol/paint mess inside the wing which I cleaned up with airbrush cleaner and cotton buds.

 

Initially, I was going to remove the hideous radiator housing as it’s completely the wrong shape at the front and has a big hole under the back. but if I did that, the removed section would be too weak near the rounded wheel openings. The plan (at the moment) is to maybe stick a piece of styrene card in and go from there. I might need to only change the front opening. I’ve got 4 different brands of New Hurricane kits to copy one off anyway.

 

I found an image of a wheel bay for a 1/48 scale model and tried to use it to sketch a design in Onshape, but although the overall width of the part was set to the newly made opening in the wing assembly, the rearmost part was far too narrow, so I had to start again measuring the actual openings in the removed part of the assembly and go from there. I still have a few tweaks to make.

 

I tried the centre section on top of the iPad and matched the image size and found the angled undercarriage door brace showed a hole, so I added extra boxing to the corners. Also, I couldn’t get the centre tank at the front to conform so I had to fillet (round off) the corners in a different order. Then I had to profile the overall shape by sketching on the end and using the extrude tool, remove the excess to form the rough shape to fit in the wings (hopefully)

 

Edited April 7, 2022 by Brigbeale

[bigbadbadge]

Oooooo another restoration   looking forward to this and your 3D work. 

Great start Brian 

Chris

[Back in the Saddle]

It’s strangely satisfying watching your efforts to transform these old models - I’ll keep an eye on this one!

[Jochen Barett]

On 04/04/2022 at 22:03, Brigbeale said:

+++

When life was easy,

RAF dayfighter? Use: Humbrol 29, 30, and 90.

[Graham Boak]

For a day fighter in 1940, yes.  But to avoid confusion, this was not the Dayfighter Scheme which came in later: this was the Temperate Land Scheme.  The Dayfighter Scheme was Dark Green and Ocean Grey over Medium Sea Grey. 

 

However, when "life was easy" I suspect the instructions said 29/30/23.  I don't know when 90 came in, but not the mid-70s when this kit first came out?  (I'm going from the instruction sheet above which is from an Airfix kit: the Revell one was in the early 60s.)  The recent Airfix instructions still point to 30 etc.

 

I'm all in favour of making old kits in your collection, but buying a made up poor kit from ebay is just masochism.

[Troy Smith]

On 04/04/2022 at 21:03, Brigbeale said:

On the underside is a marking revealing it as a Revell kit from around 1982 - so it’s 40 years old!

 

More like 1962.  That was meant as a joke but seems it's not as a quick search reveals

https://www.scalemates.com/kits/revell-h-616-hawker-hurricane--193821

 

 

It wasn't very good in 1962 to be honest.   I kinda looks like a Hurricane more than anything else....in a dim light, if you squint...

  the only bit from looking at the photos that does not look grossly misshaped are the tailplanes.... I have one stashed 'for research purposes'

 

Embarrassingly this kit got trotted out in 2020  by Revell in a BoB gift set....

https://www.scalemates.com/kits/revell-05691-80th-anniversary-battle-britain-gift-set--1260335

the Ju88 is their very good new tool, the other 3 are 60's era garbage....  

 

3 hours ago, Brigbeale said:

I’ve got 4 different brands of New Hurricane kits to copy one off anyway.

The Hurricane is something that has not been well served in 1/72nd if accuracy is factor.

the only real contenders out the box  are Arma Hobby Mk.I IIb/IIc, Airfix fro a fabric wing Mk.I, and AZ for a Mk.IID/IV/V

 

And bear in mind that a Mk.II has a deeper radiator..

 

The reasons are that many of the resources used to make them have often been deeply flawed, even if coming from a apparently respectable source.... Here is the story of the first set of accurate scale plans made, and why other were not...

HurricaneBentleynotescrop_zpsc6a2675f by losethekibble, on Flickr

 

This caught Airfix out on their 2010 kit

https://www.scalemates.com/kits/airfix-a02096-hawker-hurricane-sea-hurricane-mkiic--100264

where they used I (I presume) plans in a respectable Hurricane book (Francis K Mason Hawker Hurricane 2nd edition)  without looking at any photos...

 

Good luck with the project,  I have fond memories(and remains) of the 1/144 revell kit, which is this kit shrunk down....  but there isn't enough lipstick in Boots to make this less of a pig....

 

cheers

T

 

[KingTiger435]

Love a good restoration, will follow.

[Brigbeale]

Thanks @Troy Smith for the info. 
One of the kits in the stash is the Arma Hobby Mk1 which I’ve heard is one of the better kits out there, so I can copy parts off that.

Out of interest, I got my old (and I mean old!) Matchbox Hurricane IIC which I built when I was about 16 (I’m 54 in June so that makes it about 38 years old and is still in the paint and decals that were applied back then. (The landing gear, horizontal stabilisers and radio mast have been off a few times and the port wing has a kink in it along with the port leading edge light lens missing but the props have never been broken). `I’m not saying Matchbox got it 100% correct either but it does show differences between kits. I’ll compare them to the Airfix and Arma kits tomorrow. I’ve even got a Novo kit in the stash as well.

The stabilisers are shorter width-ways but longer front to rear. The stubs in the fuselage help with the sideways length but not much.

 

Edited April 7, 2022 by Brigbeale

[Brigbeale]

I 3D printed the main gear bays this morning and found it needed another couple of mm’s add to the length front to rear. Sideways width was fine.

I tweaked the design adding 2mm to the dimension and also added 1mm in height.

This evening, that part was printed and it fitted as intended.

 

I also added a piece of styrene card to the opening which was meant to represent the radiator housing. The front opening is just a square hole. The front opening should be a protruded oval in shape as (I believe from some pictures I looked at when I had a spare 10 minutes), later marks had an enlarged opening which is more rectangular in shape. I think I have a cure for the shape of the radiator, but I will see how it turns out design wise. I am also going to fit some sort of inner detail to the radiator as it’s now just an empty tunnel.

 

The removed section from the wings was re-fitted and is currently being left to dry before I can fill the sawn gaps and tidy up the seams front and rear.

 

 

 

[Troy Smith]

1 hour ago, Brigbeale said:

One of the kits in the stash is the Arma Hobby Mk1 which I’ve heard is one of the better kits out there

Best 1/72nd Mk.I available.  Best metal wing by a good margin,  a good kit but  requires care and some minor trimming adjustments to get the best out of it, in particular fitting the cockpit, wing fuselage join and assembling the prop.    see here https://www.britmodeller.com/forums/index.php?/topic/235080866-hurricane-mki-arma-hobby-72nd-scheme-tbc/

 

stalled because of paint issues... 

 

1 hour ago, Brigbeale said:

Out of interest, I got my old (and I mean old!) Matchbox Hurricane IIC which I built when I was about 16 (I’m 54 in June so that makes it about 38 years old and is still in the paint and decals that were applied back then.

my oldest basically complete survivor dates from maybe 1975, and is the Airfix Mk.IV,(which I've sort of forgotten about as I though a  poor kit even when I built it, and is in the shed with load of other bust kits...I built basically did a kit a week in 1975 and 76..and still have a fair amount of the wrecks.)   after that a  Monogram 1/48 from 1977.  various other fragments.  I'm just 56, so you can work out what and when...  

1 hour ago, Brigbeale said:

(The landing gear, horizontal stabilisers and radio mast have been off a few times and the port wing has a kink in it along with the port leading edge light lens missing but the props have never been broken). `I’m not saying Matchbox got it 100% correct either but it does show differences between kits. I’ll compare them to the Airfix and Arma kits tomorrow. I’ve even got a Novo kit in the stash as well

The Matchbox kit is better than the Revell, but it's not great.   

It's a bit better than the Novo, which is ex Frog of course

They all have, as you pic shows, the narrow upper nose that afflicted Hurricane kits until I think the Hasegawa kits in the 90's.

 

I never did the Matchbox in my youth, and have one (the IID) lined up for the Matchbox group build.   I got a job lot of Hurricane kits off ebay about 5 years ago, and have picked up others....  I think I now have examples of all the kits (excluding multiple versions of the same base kit) in every scale apart from some real oddities like 1/96th Eaglewall and the Kellogs freebie... 

 

and I plan to do OOB builds of them, and corrected of the ones worth the effort.   Been rather distracted by the problem of finding acrylic model paint that actually comes close to the RAF museum paint chips.... but that is  another rabbit hole...  they maybe crap kits, but I'd like the colours not to offend me...   

 

Airfix have done five 1/72nd Hurricanes over the years (six if you count the Heller IIc reboxings*) 

1957 Mk.IV .... it's from 1957, what do you expect...  maybe really a IIB (wing panelling) with a MkI DH prop.    

1973 MkI/IIB , closest really to a IIA, batteships rivets, shape is decent except upper nose, and slightly too low spine, and thus canopy) 

1978 Mk.I - raised panel lines, too thin upper nose, very basic details, otherwise decent.

2010 Mk.IIc - The nadir of the lot.....based on flawed plans.  basically wrong in every aspect. spine to humped, fin to small, wings too pointy,  much of the fuselage panel lines wrong etc etc..  Apparently builds well though.  

The only one that is really a contender now is the 2013 fabric wing Mk.I,  it's got a few detail issues,  that notice, canopy, and windscreen are too high, and the wheels are a little too big, and should be 5 spoke.

there are other issues,  but what is not really widely understood is that a Hurricane Mk.I  is a very complex subject if you want to get the details right right for a specific airframe.

Fabric or metal wing, (and there are some late fabric wings). 6 different prop and spinners, 3 exhaust types, two antennas, 3 windscreens, 5 or 4 spoke wheels,  early planes lack a rectangular hatch on the starboard side.... and a few others as well.

 

 

Having spent some time on facebook Hurricane groups, I know there is a school of thought that all marks  look the same.... which they do, kinda, until you know, and then they don't....

 

The heller kit has wings that are too wide at the tips, and too skinny upper nose, but a very impressive bit of fuselage fabric.

 

Final point, if a kit mucks up the fabric,  this just a massive PITA to fix,  and is problem in many of the 90's era 72nd  Hurricane kits, like Revell IIC/IIB, Academy IIc and The Hasegawa family do just this in one way or another...... 

 

Hope of interest....

 

 

[Bell209]

On 4/6/2022 at 6:08 PM, Brigbeale said:

I tried some airbrush cleaner to remove the grey paint/primer. Again - no effect. 

It's probably old enamel paint. I use the strong oven cleaner - it takes everything (including the pigment in my skin) off!

[Brigbeale]

8 hours ago, Bell209 said:

It's probably old enamel paint. I use the strong oven cleaner - it takes everything (including the pigment in my skin) off!

Thanks Rob.

Usually, the Dettol deals with enamel paints with no problem. 
I’ll raid the under sink cupboard to see if I can find some oven cleaner later to give it a try. 
The paint has mostly been removed by sanding sand the Hurricane is going to get a coat of Halfords finest Plastic Primer anyway.

[John]

The Revell Hurricane was great

The Revell GB version at least was moulded in green so you only had to find some brown paint to make it look like the one on the box - Humbrol 10 in my case, I would imagine. 

John 

[bigbadbadge]

Great job on yhe undercarriage Bay Brian , looks good.

Chris

[Brigbeale]

I don’t know what’s happening tonight. Twice I’ve type this only for it to disappear when it click ‘submit reply’.

Maybe third time lucky.

 

I’ve only managed small bits on the Hurricane over the past couple of nights due to other activities- though not really of my choosing.

 

The saw cuts on the under wing surfaces were filled with stryrene strips of card and given a good dose of Mr Cement S to fix them in position. The waste was trimmed off and sanded flush with the surface. Mr Surfacer was painted on the seams to fill any gaps. Other blemishes and sink marks on both the wing assembly and the fuselage were filled, again with Mr Surfacer.

That was left to dry.

 

Tonight, I sanded back the Mr Surfacer to a smooth finish. A couple of spots need more attention though.

I also measured up the Arma Hurricane’s interior framing and 3D printed a pair of side frames for the cockpit. Once printed, they were then sprue-goo’d in position using the ‘Arma instructions as a guide. They can be seen at the moment, but maybe not once the replacement canopy goes on. The original canopy is too short and not moulded well at all. It a good job I have a Falcon with two Hurricane canopies in the box.

I need to make a seat and an armoured backing plate. There was no interior detail in this Hurricane whatsoever. The pilot (or the lump of plastic representing the pilot) was just fitted on a couple of pins mounted to the fuselage half (well one - as he was stuck more to one side of the cockpit area).

 

I decided that radiator had to go, so out with the Tamiya Scriber and gradually slice through the sides near the base. The cut was finished with a knife and the the excess was sanded back. I offered it up to the Arma Hurricane radiator and the difference is massive - literally. 
The styrene card added into the hole was refitted as it was loose at one end and sprue goo used to fill the gaps. That can dry overnight so it can be sanded back again ready to receive a replacement radiator more in keeping with the size of the Arma version.

 

 

 

Edited April 10, 2022 by Brigbeale

[Brigbeale]

Tonight, I started by sanding back the dried sprue-goo which filled the edges of the styrene card fitted into the underside of the wing assembly.

While I had the wings to hand, I used masking tape to outline the landing lights and filed them out. Despite them both being the same size and depth, the plastic in one side is thinner and a gap appeared. This was filled with sprue-goo later on.
The wing tip light recesses were also filed out.

I then gave the edges of the radiator patch underneath a coat of Mr Surfacer to fill a few divots in the glue.

 

While I was working out the sizes for the armour plate, I thought ‘Why don’t I just glue the two fuselage halves together?’. So that’s what I did.

The propeller assembly would be fitted between the two fuselage halves normally, but, as the propeller is a very bad fit and can be slid forward by about 2mm, my plan is to remove the small boss on the back of the shaft and 3D print a hub to fit inside the hollow spinner. The prop shaft can then have a replacement boss fitted and, with the original hole in the front of the fuselage drilled out larger, the assembly can be fitted in position hopefully allowing the propellers to turn.

 

I fitted the aforementioned styrene card acting as the armour plate roughly cut to shape. It was glued in position using Mr Cement S and once dry enough trimmed back to make it a bit neater. I’ll dress it up with a file tomorrow. It will also need a stiffener behind it so a piece of old sprue will be fitted on the back. 
I have a generic seat in my £d printing files so I’ll print one tomorrow and fit it. I think I have some PE seat belts somewhere from another kit, so I’ll fit them if I can find them. If not then I’ll use strips of masking tape.

 

[Brigbeale]

The Mr Surfacer was a sanded back on the underside of the wing assembly, but will still need more added to fill in some divots - I’ll get there eventually.

 

I got some clear sprue and made the wing tip lamps with a 0.6mm hole drilled and painted with green and red paint. The red was superglued to the port wing and the green one was fitted to the starboard wing.

I then made the landing lights by using some thicker clear sprue and making a recess in the back with a drill bit. The divot was then filled with Tamiya Chrome Silver paint. 
Each one was then fitted to the recess in both wings with Mr Cement S. 

The port wing tip light pinged off when I dropped the wing onto the workmat. I found it again and used Mr Cement S to refit it in position. The starboard one was also given a dose of the same glue just in case it had the inclination to do the same thing.

 

While the glue was setting, I got the 3D printed seat off the printer and cleaned them up a bit (For some reason, I had them print as a pair). After a quick test, it was sprue-goo’d into position.

The Mr Surfacer on the fuselage centre seam was sanded back, but will again need another coat as the joint is still visible in places.

I wasn’t overly happy with the top of the tail-fin where the plastic on one side broke off, so I filled it with sprue-goo as it’s quicker than using thin layers of Mr Surfacer.

 

The clear sprue on the wing was dried enough to work with, so the landing lights were sanded back using a nail sander with various grades. The final step was to polish the surface. I’m going to let the wing tip ones dry overnight before I touch them with the sanding stick- just in case……

 

The Hurricane fuselage dry fitted to the wing assembly.

Edited April 13, 2022 by Brigbeale

[Brigbeale]

While I wait for the photos of tonight’s escapades upload from the IPhone to the iPad, I’ll get on with typing this.

 

I started tonight’s proceedings by sanding back the starboard wing tip light using the same method as I used on the landing lights.

However, when I went to sand back the port wing tip light, it pinged off again. I found it under the sofa about 8 feet away! Thinking the superglue was acting as a barrier between the wing and the sprue that I made the light from, I lightly sanded both and used Mr Cement S to fix it back in position.

 

I then sanded back the sprue-goo on the tail fin which was used to fill a break on the starboard half at the top. It looks a lot better now. I also carefully sculpted more sprue goo on the rudder trim tab area where another break had happened when the two halves were separated.

 

The cockpit interior was brush painted with Tamiya Cockpit Green, while the seat and undercarriage bay were given a coat of Aluminium. I also painted the armour plate black for a bit of contrast. I then noticed during another test fit of the wing assembly, that the upper surface of the upper wing/cockpit floor area could just about be seen, so I painted that with cockpit green as well.

 

While looking for the PE seat belts (which I’ve still yet to find), I found a boss/hub attached to a piece of sprue - no idea where it came from. I used it to fit the propeller in position. The cold boss was snipped off the back of the propeller. The hole in the new boss was enlarged to fit the propeller shaft and the propeller shaft was then inserted into the original opening in the front of the fuselage. With the wings still off, I could get to the back of the propeller to fit the boss. A light application of Mr Cement should hopefully hold it in position. If not then I can resort to making a boss on my 3D printer for it.

 

The port wing tip light was finally sanded back and polished and it stayed in position this time.

 

I couldn’t put it off any longer. I fitted the main wing assembly to the fuselage. The original placement of the wing had a big gap at the front where it meets the lower engine covers. I was able to push it forward to close the gap and remove the step between the two parts as the curved shape of the wing pushed it into the correct position. Two thin elastic bands were placed under the wings and over the fuselage to hold it. Then a dab of Mr Cement was placed on each side of the rear wing to fuselage joint. The gap is now at the back but it will be easier to fill as it’s flatter than the front joint would have been..

Also, I thought ‘What the heck’ and I fitted the rear stabilisers as well - but straight this time and not drooping like they were originally. 
 

The Hurricane is not in the model stand while the cement dries. It looks like a Hurricane once again - maybe not an accurate rendition but the object of this restoration was to give the old model a second lease of life - and not try to make a silk purse out of sow’s ear.

Edited April 14, 2022 by Brigbeale
Photos added

[Brigbeale]

Tonight, I started by unsuccessfully searching for the missing PE seat belts. I had them fairly recently so they should be near to hand but I can’t find them anywhere I’ve looked.

As a result, I just opted to fit the belts made from Tamiya tape instead. Once fitted, they had silver pen dotted on to represent buckles, although the silver doesn’t show up that much against the aluminium on the seat.

 

Now the cockpit was complete (albeit missing the IP and control column, but there’s not much that can be seen inside the cockpit anyway.

 

The replacement canopy was next, which came from a Falcon Canopy (Set No 2 RAF Fighters WW2). This one was cut out easily as most of it was straight lines. The only curve was the top rear. I just cut it out with excess and used the nippers to firm the excess away. The edges were tidied up and the canopy was fitteid in position - closed at the moment but I may cut it to have it slid back. I’m not looking forward to masking it though, but it has to be done. It would be nice if Falcon included masking kits as well.

 

Next up was the missing propeller blade. I got a strip of Tamiya Tape and placed it on one of the remaining propellers. Using a sharp blade, I scraped away at the edges until I could see the plastic appearing. the ends were trimmed off and the newly made template was placed on a price of 1mm styrene card. Nippers were used to trim the corners back close to the shape of the tape template and a sanding stick was used to make the styrene card the same shape. The tape was removed and the propeller was sanded front and back on a diagonal to represent the shape of the propeller blade.

A dry fit to the remains of the original gave me an idea to cut a small slot at an angle in the stub and insert the blade into it. The end of the propeller blade was thinned slightly to get it to fit. Mr Cement S was sued to fix the propeller blade in position. Once the cement has set, the blade can be revisited with a knife to scrape the sides near the hub to match the other two blades closer.

 

A piece of 0.5mm styrene card as inserted into the gap at the rear of the wing where it meets (or is supposed to) the bottom of the fuselage, glued in place with MC-S (Mr Cement S). 
 

I then got some Vallejo acrylic putty and filled the fuselage to wing joints. When the tops of the main wings were cleaned back, only a thin line was visible, so I’m happy with that. 
Once they were all filled, I went around the Hurricane with Mr Surfacer to make sure any remains seam lines were covered.

 

The Hurricane is now in the stand again to allow the MC-S and Mr Surfacer to dry fully for tomorrow’s work sanding and masking. 
Cant wait!!

 

[Brigbeale]

Progress had slowed on the Hurricane as it was a case of adding Mr Surfacer to the seams, waiting for it to dry and sand it back only to still see a trace of the seam line again. I think I’ve got them sorted now.

 

I photo-copied the template from the Arma Hobbies Hurricane instructions and cut out the sliding hood masks for the canopy. The fixed front masks were too small, so they had to be made by placing the tape on and cutting them out in situ with a sharp knife. I knocked the canopy off while doing this but it helped in the end without being fitted to the fuselage. I just refitted it again afterwards.

 

I decided to copy the Airfix MK1 Hurricane radiator in the end. The front part was easier to design than the rear part. The first attempt was ok but the rear section was too flat sided. I thought I’d  just add some filler to reshape it, but in the end I re-designed it. I couldn’t quite get the side curve to match up with the bottom curve and had a line where the two met. I printed it anyway and then fitted it in to position. 
Even without the finishing touches (filler), it looked a whole lot better than the original offering.

I gave it a good smear of Revell Plasto filler this morning. That should be dry enough to sand back this evening (where I should have just enough time to sand it and then go for my hospital appointment for a scan on my right ear to see if they find the cause of the Tinnitus).

 

[KingTiger435]

Great progress, I applaud your patience with all the filling, sanding and correcting.

[bigbadbadge]

Crikey Brian , a lot of great work k fella, this is coming on well.  Hope you  can  get you Tinnitus sorted.

Chris