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Here's a photo of the Cold War Gallery in the Air Force One Pavilion. This photo was sent to me by Todd Carb.
Civil Defense poster scan and Thunderbolt siren head supplied by the Civil Defense Museum.
Here are all of the pieces that will make up the display siren. The siren chopper motor parts, rotator support and rotator motor plate (not pictured) are all left over unusable pieces from the Valley View job. The horn, screen, horn support and chopper motor housing are all from a pile of sirens that came from Gainesville Texas. I removed the rotator driven gear and replaced it with an aluminum sleeve (seen on the rotator support tube in the photo). The siren motor armature, rotor and windings have all been removed from the chopper motor as well. I even cut some material out of the rotator motor plate to reduce weight.
New Rotator Box
All the rotator box pieces I had weren't in good enough shape to use for this project so I asked my employer Regal Research and Manufacturing about making a new one. I had to draw-up new working drawings from parts I had so they could build the new box. The pieces were cut on a CNC laser machine and then bent to shape in the brake department. The tube on top of the box was then welded in place. The original Federal box has a seam and rolled over edge to attach the tube to the top. I was a bit nervous assembling the box after the work was done. If I had made any mistakes on my drawings they would show up while I was putting the thing together. The box assembled fine and all turned out great.
Parts After Blasting
Here are all the parts except the rotator box. The rotator box was out to the plating shop when I took this photo. I had the parts "media" blasted but I think that the blaster must have had some sand in the mix because the finish came out far rougher than I thought it would. The yellow piece hanging on the horn is a sample of the color powder coat that will be put on it. The yellow is a bit bright but it's the only color we had in stock.
Powder Coating The Parts
Regal has a full paint and powder coating facility so I decided it would be easier to put the color on the siren there. There was a color of yellow powder in stock that we regularly use but the yellow is a little brighter than the original color but not enough to really matter. The photo on the left shows the chopper motor frame/stator and the chopper motor tube ready to powder coat. The photo in the middle shows the horn and some misc. hardware parts after taking them out of the oven. The photo on the left shows the all the other pieces after powdering right before putting them in the oven. When powder coating is done the pieces are covered in a colored powder which is then heated in an oven to melt the powder into a layer onto the pieces being coated.
All Together And Ready To Go