An Avro 748 in a similar test frame.
The Vulcan was 'nose on' at the other end of the hangar.
Most, if not all, accounts of Vulcan production are "one aircraft missing"
The forgotten aircraft is, of course, the STS (structural test specimen) that led such a lonely and tortured life in No.5 hanger, Woodford flight sheds.
Few people know anything at all about this aircraft until now - this is her story...
She came down the production line, like all her sister aircraft. Apart from the fact that she had no hydraulics, or electrics - or any other systems for that matter, just a bare airframe. She was also unpainted. Caged in a massive steel frame, her outer skin was covered in attachment points connected to steel ropes leading to lead weights of quite enormous proportions. Also connected were literally thousands of electric strain gauges, wired into the "Control Room" - a glazed room packed with instruments and set at a high level in the hanger, giving a very commanding view of the "torture victim"
The loads placed on the airframe were very precise. Although hydraulic jacks lifted the weights, it was the weights themselves which actually applied the loads. Hydraulics could not be relied upon to apply accurate loads due to the varying seal friction within the cylinders.
So there she was, like a caged animal, festooned with all manner of equipment ready for the tests - and tests they were.
No time could be lost. This was a "24/7" operation. She had to be several hundred hours "flying time" ahead of any other aircraft in service. Any defect in design had to be exposed in time to work out a remedial repair scheme and apply it to all aircraft on the line and in service.
She "flew" in her steel frame, controlled by a programme from the Control room, and for a person to stand underneath her was a very frightening experience. The sounds of tortured and screaming metal had to be heard to be believed. Certain flight "events" deflected her wing tips 6 feet and more.
A "Flight" commenced with a full fuel loading, 10,752 gallons, and of course, a full "stores" load (Avro's euphemism for bombs) The "stores" would consist of 21k lbs of Iron bombs, or 2x Douglas Skybolt, or 1x Avro Blue Steel. Next followed the take off at full power, a steep pull-out from the field a and climb to altitude. There then followed a series of "events". These consisted of "gusts" and "evasive manoeuvres" to avoid missiles and simulate storm weather conditions and stratospheric winds. Then a rapid decent (could be 15-20,000ft in 90 seconds), for the release of "stores", the sharp turn away from the target and the return journey to the field, also packed with "events". The "Flight" finalised with very sharp turns to finals, an extraordinarily heavy landing and pull-up without braking chute. The "landing" was particularly notable, it was hard to know how the airframe could withstand this on a regular basis - the sound of screaming metal was alarming.
If she was not suffering enough, from time to time, the "flying" stopped, for "full load" tests to be carried out. These were real occasions, with the hangar cleared, all doors locked and all staff moved into the Control room. The loads applied were enormous - we were literally trying to tear the aircraft apart. Over time, the loads were increased, 50%. 60%, 70% and more, of the maximum design limits. Sometimes the "bangs" from the structure were like explosions - when this happened the loads were instantly removed and technicians then swarmed over and inside the structure to discover what had failed.
After years of this treatment, she was removed from the test frame and scrapped without ceremony. Few people ever knew what was going on "behind closed doors" or what a contribution our "forgotten Vulcan" made to the V bomber programme.
Copyright © 2000 Raymond Goodall
