NASA Johnson Space Center
Oral History Project
Edited Oral History Transcript
David Wilson
Interviewed by Jennifer Ross-Nazzal
Chantilly, Virginia – 22 March 2012
Ross-Nazzal:
Today is March 22, 2012. This interview with Dave Wilson is being
conducted at the [Smithsonian National Air and Space Museum] Steven
F. Udvar-Hazy Center in Chantilly, Virginia, for the JSC Oral History
Project. The interviewer is Jennifer Ross-Nazzal, assisted by Rebecca
Wright. Thanks again for joining us this morning.
Wilson:
Oh, you’re welcome.
Ross-Nazzal:
We certainly appreciate you taking time out of your schedule. Tell
us how you became involved with the preservation efforts on the [OV
(orbiter vehicle)-101] Enterprise.
Wilson:
The project was going for a couple months with a very limited crew
on it, probably three, four, maybe five people here at the Hazy Center,
and I was out at the [Paul E.] Garber [Preservation, Restoration,
and Storage] Facility. Since I’m the person that does a lot
of the ordering on the paints and supplies, I was in constant contact
with Ed [Edward M.] Mautner. He was the lead on the project, and I
was hearing that they felt kind of overwhelmed. They had a lot of
work to do, they had a limited timeframe to get it done, and it just
didn’t seem like they had the manpower available.
I approached my supervisor and volunteered to go onto the project
because I felt like I could probably make a difference. He was a little
bit surprised, actually. It was obvious that he didn’t consider
me as a person he was going to put on the project, but he was glad
to accept and sent me out to work on the project. I think that the
crew out here was pretty happy to have one additional person. Even
though it probably still wasn’t enough people, they were happy
just to have a few more hands out here.
At that point, they were still in the process of cleaning the exterior.
They had already started the prep work on the side walls and had experimented
a little bit on the cargo bay doors but hadn’t gotten too far
there. In the months leading up to that, I had heard that they were
having a lot of problems getting a consistent finish on the side walls
with the methods that they were using. I’d send them out various
grits of sandpaper, and I kept hearing back that they weren’t
making much progress. I really didn’t understand what the problem
was, but it became obvious the first day that I went up and started
trying to do some sanding on the side walls.
Thinking that it was a space artifact, I thought it would have a polyurethane
or some sort of aerospace coating, but what we failed to take into
account was that prior to being given to the Smithsonian, it was at
the World’s Fair [1984 Louisiana World Exposition], and apparently
they had done a spruce-up on it to make it look better. They had painted
a lot of the exterior surfaces, the side walls and the upper doors,
with latex paint. We found that in some areas there was actually five
layers of latex paint, and it just doesn’t sand anything like
an aerospace-type coating.
Here I was sending all these fairly fine grits, and they really weren’t
even putting a dent into the surface that needed to be prepped. We
went from a 400-grit paper down to eventually having us start with
an 80-grit paper, which is a very aggressive grit that you would probably
never consider using on something like this, and then we’d step
up eventually to 180- and 220-grit paper to finish it out with.
I probably worked for the first three weeks to a month on just sanding
the side walls. We were using a random orbital sander. Myself, Ed,
and Tony [Anthony W. Carp] took turns. We had a special setup that
really only allowed two sanders to work at the same time. It had a
special dust collection system, and it had a limited run of hose,
so we had to work side-by-side. Early on, it was primarily Tony Carp
and myself that were side-by-side on the side walls.
It was interesting because we’d get into sort of a groove. It
was almost like one person didn’t want to stop first to take
a break, so we were seeing who could outdo the other person, who would
be the first one to actually take a break. We’d sit there sanding,
and I’d see him kind of looking at me, and I could tell he wanted
to take a break but he didn’t want to be the first one to stop,
and I’d keep going. We kept pushing each other, and as a result
of that I think we probably covered a lot more ground than we normally
would have if we were working individually. The fact that we were
side-by-side kind of made us push each other.
And it was fun. The project as a whole was pretty demanding physically,
and I think it was one of the reasons why some of the other folks
in the shop probably weren’t enthusiastic to volunteer. Thinking
about the overall project and what it meant, it was something that
I felt like I wanted to get involved in. I wanted to be part of it
because I saw it as a once-in-a-lifetime opportunity, and it’s
something that we could be proud of in years to come and something
that we’d talk about a lot, and we do.
There’s not too many people that can say that they painted a
Space Shuttle. Sometimes you get in conversations and people ask you
what do you do for a living, and you start telling them, “Well,
you know, we painted the Space Shuttle,” and you get that funny
look like, “Is this guy pulling my leg, or is this for real?”
Ross-Nazzal:
Had you been a space nut prior to this?
Wilson:
Not really. I’m probably more of an airplane person than a space
person, but beyond that, I’m a paint person. My specialty area
is painting. I knew that this project was going to require a great
deal of painting, and it was probably going to be something unique
compared to what we had done in the past, and I just felt like I’d
wanted to be a part of it.
Ross-Nazzal:
What other projects had you worked on before you started working on
Enterprise?
Wilson:
One of the first projects that I got on when I started working at
the Smithsonian was the restoration of the Hawker Hurricane [aircraft],
and that’s on display out here at the Hazy Center now. That
was one of the last full-up restorations that we’ve done at
the Garber Facility before we did the switchover to getting everything
prepped for the Hazy Center. Hopefully in the near future we’ll
shift into full-up restorations again.
Aside from that, I’d worked on the [Stinson] L-5 [Sentinel aircraft],
we did an overall paint job on that. I’d done some work on the
Dornier Do 335 [Pfeil aircraft], some paint work on the [Curtiss]
P-40 [Warhawk aircraft] that’s hanging out in the museum. Also
the Heinkel [He] 219 [Uhu aircraft] fuselage, which has this interrupter
pattern, camouflage on it. That was an interesting project that I
worked on, and did most of the painting on that. Ed Mautner and myself
did the camouflage on the top of it. He took one side and I took the
other, and it was another interesting and fun project.
Ross-Nazzal:
What lessons learned from those projects did you take to this project,
or was it something completely different?
Wilson:
I think just knowing what goes into the preparation for a large-scale
project helped for planning for the Enterprise, but it was a totally
different animal in a way. We ended up using rollers and rolling the
paint on the Enterprise rather than spraying it. I think that was
the biggest difference, whereas everything else we had done was all
spray application.
Ross-Nazzal:
Tell us, how long did it take you to finally get all that latex paint
off?
Wilson:
Oh, boy. It took months and months of work. The side walls were probably
the easiest because they were mostly flat and it was all done with
a random orbital sander, which wasn’t too bad, but when we got
to the cargo bay doors, that was the real challenge. Part of the stipulation
we had was that they were still considered flightworthy spares, so
we had limitations on what sort of abrasive we could use or the type
of equipment we could use on it.
Early on we were told we couldn’t put any weight on the doors,
we couldn’t walk on the doors. Somewhere down the line in the
initial processes of doing the stripping, we found that we couldn’t
get past actually getting out and standing on the doors. There was
no way we could do it. Leaning over the scaffold and the odd position
that it would put you in, it was just physically impossible.
We had that discussion among us on the team, and we still weren’t
sure if we could get around it. Then a couple days later it got to
the point where I realized I just can’t do this, I can’t
get to these areas. I think I was the first person that stepped down
on the doors and squatted down and started scraping. About 10 or 15
minutes later I heard this, “Hey, you’re on the doors.
What are you doing on there? I thought you couldn’t do that.”
I said, “Well, I’m doing it. I don’t see how we
can get around it.” And then slowly after that everybody followed
suit because they realized that was so much easier than what we had
been doing. We kept it spread out, we tried not to concentrate the
load in any one area.
The stripping of the paint on the doors was all done with a heat gun
and a putty knife. Somebody within our group came up with the idea.
I think it might have been Steve Kautner, who’s moved on to
another job. We found that was really the only effective method, to
use a heat gun and then work a small area and scrape it with a putty
knife. It was really time-consuming, and it was really hard on our
hands.
One of the biggest problems I saw with the whole project was that
short-term it had really wrecked my hands, and a lot of people were
having the same problem. It continued for almost a year and a half
after that project was done. I was really concerned that it was carpal
tunnel [syndrome] and that it was going to be a constant thing I was
going to have to deal with, but slowly but surely it subsided. Then
after a year and a half or so, my hands feel like they’re back
to normal. It was tough sitting there scraping all day long for eight
hours a day. We’d try to switch the putty knife back and forth
from hand to hand, but that only gave a little bit of relief.
The whole process was tedious, and it was tough because the skin was
such a thin layer of aluminum over a composite, that if you concentrated
the heat in any one area for too long it would actually blister the
top skin. We did do that in quite a few areas before we got the hang
of it. In a very short period of time we got the method down. It took
each person a little bit longer, depending on the way each person
worked, but we very quickly kind of got the hang of it and were able
to move through it without doing any damage to anything.
Ross-Nazzal:
Were you wearing any special clothing or respirators as you were working
this process?
Wilson:
When we did the sanding we had a half-mask respirator on, and most
of us wore a Tyvek suit just to keep us clean. There was a lot of
dust and residue that you were kicking up. When we got to the scraping
on the doors, we mostly wore a half-mask respirator because we were
getting a lot of vapors from the heat gun process. We wore gloves
to protect our hands. Some of us did wear Tyvek suits as well, just
to keep clean. Really the important thing was the respirator and safety
glasses, and then the gloves because of the heat buildup on the skin.
It dissipated pretty quick, but if you were to get up against the
heat gun, it’d give you a pretty nasty burn.
Ross-Nazzal:
And you were doing this while the public was watching?
Wilson:
Yes, it was kind of neat. They had built a framework of scaffolding
over the Enterprise, and it kind of looked like giant monkey bars.
So here we were, traversing this every day, up and down, and down
for breaks and then back up again. When we were up on the top of the
scaffolding and working on the doors, we had to wear a harness as
well.
We had a full harness with a tether to one of the scaffolds, just
in case we were to slip. It was a long ways down from the cargo bay
doors down to the floor. It was a little bit cumbersome, and it made
things a little bit difficult, but I think we all coped with it pretty
good. You got used to it after a while. There were certain limitations,
but it’s something that became second nature after a while.
Ross-Nazzal:
Once you finally scraped off all that paint, were you in discussions
with NASA or USA [United Space Alliance] about what type of paint
to use, or did you have an idea of what you should be using given
your expertise?
Wilson:
I did have some discussions with some of the folks at [NASA] Kennedy
[Space Center, Florida]. I got the original spec [specification] on
the paint, which was a urethane paint, and got the original color.
It was actually a variation of Insignia White. From there I concluded
that a comparable paint, a polyurethane, would be the way to go. We’ve
had a longstanding relationship with PPG [Industries] paints here
at the Smithsonian, and in the past they’ve given us a lot of
support and donated materials.
I started contacting the people that I knew at PPG, and found out
that PPG had recently acquired PRC–DeSoto, which is an aerospace
military coatings company. It was an area they were a little light
on in their product line. PPG more concentrated on automotive paints,
but they had taken over the PRC–DeSoto line to give them the
market for military coatings. My contact here in PPG put me in touch
with a rep [representative] out on the West Coast.
His name was Duane Utter, and he was one of the managers for military
coatings and specialty coatings. In discussions with him I was trying
to figure out how we were actually going to apply the paint. We knew
we had to do it in the museum because the Shuttle was already here,
and I didn’t think there was any way with the square footage
that we had to cover that we could actually do it by spraying. There’d
be too much overspray, too much fumes that we wouldn’t be able
to exhaust, so I was looking for some sort of alternative way that
we could do it.
When I got in touch with Duane, he mentioned that on large airliners
they had a specialty product, a flow additive that they add to the
paint. It actually allows you to roll the paint on with a low-nap
foam roller. I’d never heard of such a thing. It was kind of
intriguing, but I was skeptical at first because all my expertise
had been in spraying. I’d never had really much experience with
rolling paint except for house paint. I never would have thought that
you could have rolled a polyurethane or an aerospace paint.
My initial thought was it seemed like a ridiculous idea, but the more
that I looked into it—he sent me some tech [technical] sheets
on it and some shots of some guys rolling an airliner out on a pad
somewhere—and I thought, you know, maybe there’s some
merit in this. This actually looks like it might be the perfect solution
for what we’re doing. Obviously you’d get some vapors
coming off, but you have no actual overspray, and there’d be
a lot less hazards to work with than trying to spray it.
So we talked it through, and he decided that he would offer some samples
for us to try. He sent me out a gallon of white paint, a gallon of
the roll additive, and the reducers and hardeners and all that went
into the paint. I set off at Garber doing some test panels, trying
to figure out how this stuff would work.
There was certain ratios to mix the hardener and the paint and the
reducer in, and then you had a range of options on the flow additive,
different amounts to give you different flow characteristics. I just
started experimenting with different amounts. My main concern was
on the side walls. Being that it was a vertical surface, I knew that
was where it was going to run the most.
I did all my test panels vertically because I knew if I got it to
work well vertically that the sections of the door, which curve up
from almost vertical to almost horizontal, wouldn’t be a problem.
I found that the ratio that worked the best was about six ounces of
roll additive to a mixed gallon of paint. That was what we ended up
going with, and no reducer for the whole mix. We found that the roll
additive actually acted as a reducer, and that the reducer that they
recommended wasn’t needed at all.
Ross-Nazzal:
Did you have to prime the vehicle as well?
Wilson:
Yes. One of Duane’s recommendations was to use an aerospace
or military epoxy primer that they have. It was called an Eco-prime,
and it’s basically a chromated epoxy. They used it primarily
for military applications like naval aircraft where corrosion resistance
was an issue. Knowing that the cargo bay doors were aluminum and we
were going to be painting the bare aluminum, I wanted to make sure
that the topcoat had a good base to bite into. I was concerned that
we needed a very good epoxy primer that we could put on as a base,
so the Eco-prime ended up being the perfect solution.
We actually were able to put the roll additive into the primer as
well, about the same ratio that we used in the topcoat, and applied
it very similarly. I did the same kind of test panels first, applied
the primer and then went with their recommendation, a five-hour flash
time, and then we were able to topcoat it.
When we actually did the Shuttle, we found out that we really couldn’t
do the priming and the painting all in one day because it would push
us too far into the early morning hours. The fear was that the hangar
wouldn’t evacuate the fumes well enough before the public got
there the next morning. We were trying to limit the amount of time
that we actually were painting in the evening, to give us plenty of
time between the time we knocked off painting and the time the public
arrived, so that the hangar would be well cleared of any vapors or
fumes for safety purposes.
Ross-Nazzal:
There’s also some foam and wood, I understand, on the vehicle.
Did those present any challenges since you’re also working with
aluminum?
Wilson:
Yes, they did. The Enterprise, being that it doesn’t really
have any real tiles on it, is all simulated with foam tiles. What
NASA had devised for painting that originally is a 3M product called
EC-2241, a specialty elastomeric paint that they used.
They took this base product, which was white and color, and then they
added a ground mica material to it to give it a certain sheen, as
well as what they call a Degussa [phonetic] powder, which is a flattening
powder. Then you mix it all by a certain weight, and that would give
you the material that they applied as a topcoat on the white foam
tiles. To do the black it was the same mix, but then they added a
carbon black powder that gave it that black look.
I had received the tech sheets from Kennedy on how they originally
formulated it. We followed it through, and I found that when you did
the black paint, adding the carbon powder actually made it very coarse
and gritty. We found that the way to get around that was after you’d
mixed the whole thing, to strain it through a heavy bronze filter.
That actually gave you some very workable material where otherwise
it was almost unworkable, it was too lumpy.
Ross-Nazzal:
And the wood, did you treat it in any different fashion?
Wilson:
We did have wood on the OMS [orbital maneuvering system] pods. They
were units that were made to simulate the original pods, but they
were really just mock-ups of the originals. They were in pretty poor
shape. We had a lot of problems with some mold on the interior of
the pods. When we brought them into the shop at Garber, we ended up
completely rebuilding them.
A lot of the wood structure had some rot in it, and the mold had become
an issue early on. We thought it was a possible health risk, and we
actually had our safety people come in and do an assessment of the
mold to make sure it wasn’t too dangerous. It was deemed that
it wasn’t the type that was of great concern, so we went about
removing all the rotten members out of the OMS pods and replacing
them with new.
For the exterior skin of the pods we used a lot of West System epoxy,
which is a common epoxy that’s used to do the exterior of wooden
hulls on boats. We found that to be very effective. We mixed the West
System epoxy with microballoons and found that was very workable.
We could mix it almost to a molasses consistency and spread it out
over the surface of the pod, and then come back usually within about
24 hours and do the final sanding and shaping of the outer skin of
the pods.
From there we actually used the same paint that we used on the cargo
bay doors and the side walls. We used the Eco-prime primer and then
topcoated it with the military spec polyurethane in the same fashion.
It was all roller-applied, except there were a few pockets on the
pods which made it really hard to get into with a roller. We mixed
it in a spray gun, and then sprayed into those areas after we had
rolled the exterior surfaces, just to make it a cohesive paint surface
on the exterior.
Ross-Nazzal:
How long did it take you to paint the entire vehicle?
Wilson:
The actual painting process was about four nights total, but it was
spread over about a two-week period. We started with the cargo bay
doors first. We started from the left rear, did one side and worked
from the rear to the front, and then went to the right rear and worked
from the rear to the front of the vehicle.
We found that working in teams of four was the best way of going about
it. We had two people stationed at the bottom of the doors and two
people at the upper end of the doors. There were seams that went vertically
on the doors that separated it into sections, and we tackled each
section individually, all four of us tackling it at once. We had the
two people at the top start at the center, the two people at the bottom
start at the center, and then we worked from the center to the top
and to the bottom, respectively.
We found that the key to the whole rolling process was going through
a dry rolling application. We would put a medium to wet coat on, we’d
roll out about a 10- to 12-foot square area, and then we’d take
the roller and ring it out in the roller pan to where it was almost
dry. Then we’d go back over top the area that we had just rolled
and found that that was the key to making sure that we didn’t
have any sags or runs starting. That gave us a consistent finish that
looked very much like a spray finish.
The first night we did the priming of the cargo bay doors, we did
both sides in one evening. Then we let it sit for 24 hours, came back
the next evening and we did the application of the topcoat, the white.
Did one coat, then took a look at it when we were done and determined
that one coat gave full coverage, looked very consistent. We were
satisfied that one coat was enough for the cargo bay doors.
Then we continued to do some prep work on the side walls, and came
back three or four days later to do the side wall paint application.
We did the priming of both sides in one evening, then came back the
next evening and did the application of the white. The side walls
were a little different in that we didn’t completely strip them
to bare aluminum like we had on the cargo bay doors.
Essentially we had a bunch of spots where we had gone down to bare
aluminum, and spot-primed with this Eco-prime on those bare aluminum
spots. Because of the nature of the primer, it was actually a bright
greenish yellow color, so we weren’t sure how that was going
to cover. We did one application of the white topcoat, and it almost
covered. It was so close, but when we stood back you could just faintly
see a little splotchiness here and there.
It took us probably two or three hours’ worth of application
to get both sides done. It was like midnight or 12:30, and the four
of us were there. The three guys turned and looked at me and said,
“What do you think? Is that going to do it?” I looked
at it and I said, “No, I don’t think so. I think we’re
going to have to put a second coat on.” Everybody was pretty
good with that. I think they wanted to go home, but they knew that
we needed to do it, and everybody dug in.
We went down and mixed another batch of paint and started putting
that second application on. It ended up that we didn’t get out
of there till about 3:00 or 4:00 in the morning, but it was well worth
it. The second coat made a huge difference. I don’t think we
would have been satisfied if we had walked away with only that one
coat.
Ross-Nazzal:
Did you have them run through a practice session, to try this on the
ground before going up on the vehicle? Or did you just assume everybody
was going to be a good painter?
Wilson:
I was probably the only one that did practice on my test pieces. That
practice was really for the purpose of getting the roller additive
right, knowing that the mix was going to work the way we wanted it
to. We didn’t do a dry run at all as far as how we were going
to apply it.
We did get together right before we actually went up and started painting
the first coat and decided how we would break it up into teams and
how big of an area we would try to do at a time, but we learned as
we went. We figured the primer coat probably wasn’t as critical
as the topcoat, so we had a little bit of time to practice. We knew
if we had to, on the primer coat we could come back and sand it if
it didn’t come out the way we wanted it to.
Luckily it went very well. The first coat went on pretty smooth. We
figured out pretty quick that the dry-rolling was really the way that
perfected it. We started out on the first major section and didn’t
do the dry roll, and we were having problems with some sags and such.
Then we thought, wonder if we dry-roll this if that would work. We
tried and went back over a little section and saw that that really
smoothed it out.
We were able to go back on that first section before it had a chance
to set, dry-roll the whole thing, and then stand back and realize
this is what we have to do for the whole process. This is the only
way that’s going to make it come out right. Went from there
and used that process on the whole rest of the Shuttle.
Ross-Nazzal:
What kind of prep did you have to do on the vehicle as you were painting
it?
Wilson:
Prior to the actual application of the cargo bay doors, after we were
completely done stripping it—we’re down to bare aluminum
now, this was with the scrapers—it still left a little bit of
residue here and there. So we ended up making our own sanding pads
out of Scotch-Brite pads. We took square pads, cut them down to rounds,
and then we made a special backing plate so we could apply them onto
six-inch random orbital sanders.
Then we very carefully went over all the cargo bay doors to get any
last-minute residue off little places that we couldn’t get to.
Once we did that we were pretty satisfied that we had a nice consistent
finish to apply paint to. We used a PPG product, DX330, which is a
wax and grease remover called Acryli-Clean.
Because of the sheer size, of the square footage of the doors that
we were going to need to preclean—everybody got up there, took
a section. We had our Tyvek suits on, we had booties on, and we had
gloves on so that we weren’t touching it and leaving fingerprints.
Then we went through with the DX330 with rags. We’d do a wipe-down
and then wipe off with a clean rag. Go through the whole procedure
as prescribed by the manufacturer, which is essentially to not let
the cleaner dry on its own; you wipe it off before it has a chance
to air dry.
Once we had the doors all clean, we used an Alodine [chromate conversion
coating] on them. This was done with a sponge mop. We were scratching
our heads about a month before we actually got to this, and we were
trying to figure out how we were going to Alodine the whole surface.
Reading some of the tech sheets on the Alodine, they recommended on
large areas that you could use sponges. We thought about that and
then realized, what about sponge mops. Maybe that would actually work
better, because you’ve got that long handle, and if you get
the kind that has an attachment where it wrings out the sponge, that
would be perfect. The access we had to them from the scaffolding,
we could actually reach everything we needed to do without actually
standing on the doors.
So that was what we did. Ahead of schedule, about a month before the
actual application, I sat down and started ordering all these supplies.
We got six buckets and we got the sponge mops and got the Alodine.
The process we used, we poured the Alodine full strength into the
buckets. Decided that was probably the best way to do it, not to dilute
it. We used a Henkel product, 1201 GL Alodine.
We, again, got a couple people top and a couple people bottom on the
scaffolds, started at the middle, and we worked our way top and bottom.
Applied it one application. It has a tendency to want to bead up.
The trick is keeping the surface wet, so we would apply it, wring
it out in the bucket, and then apply another coat on it. Do that continuously
for about five minutes, which is the dwell time on it, trying to keep
the surface completely wet the whole time so that it doesn’t
develop a dry spot.
Then after that five minutes we wring it out in a clean bucket of
water, go over it with the mops. Work this time from top to bottom,
let the water run to the bottom, and we catch it with a sponge mop
so it didn’t pool up at the bottom and run down the sides of
the Shuttle. We’d keep doing that until the water sheeted clear
over the Alodine. That’s when you know you have a good bite
to it, then it’s thoroughly rinsed off.
We were very careful after we applied the Alodine not to touch it
with our hands, because we didn’t want to leave fingerprints
or anything that would cause an adhesion problem. I think maybe a
day or two went by between the Alodineing process and the actual first
topcoating of the primer on the cargo bay doors.
On the side walls, most of the surfaces were just sanded paint. We
had a few breakthrough areas where we went to the bare aluminum. We
spot-Alodined those areas, and used the same process where we wash
it with clean water. In those areas we were able to just use a handheld
sponge. That was the way we tackled the prep work on the bare aluminum
surfaces.
The rest of the painted surfaces, they’re wiped down with this
DX330 Acryli-Clean, which is what it’s made for. There, again,
each person would tackle an area and we would go at it with a wet
rag of Acryli-Clean, then a dry clean rag that we would wipe it down
following the prescribed method.
Ross-Nazzal:
How much paint did you guys end up using?
Wilson:
I had to do the figuring initially on how much square footage that
we thought we would cover. Dealing with PRC-DeSoto—who I might
mention actually donated the paint to us. After I initially talked
to Duane Utter, he alluded to the fact that they might possibly be
able to work out a donation. I got in touch with our development office,
and a couple of the folks there started dealing with Duane out on
the West Coast. They were able to come to an agreement that they would
donate all the materials we needed.
I was having a hard time finding at the shop a scale drawing of the
Enterprise, or something that I could figure the square footage. I
ended up finding a 1/72nd scale model that had been sitting around
in our conference room for years. I took that, and took all the measurements
of the side walls and the cargo bay doors, and then multiplied it
up by 72. It was about 4,275 square feet that I ended up figuring.
I sent that information to PRC-DeSoto and I let them tell us how much
paint we were going to need. They ended up sending us 20 gallons of
the white and 10 gallons of the primer. We only ended up using about
half the amount that they sent us. I’m not sure if that was
because they were anticipating we were going to have to roll on two
coats on all the surfaces, and we ended up on the cargo bay doors
with only one coat versus the two on the side walls, or if when they
did their calculations they were actually thinking of a spraying application
rather than the roller application. For whatever reason, we only ended
up using about half the material that they actually sent us, so we
still have a lot of that stuff left over.
Ross-Nazzal:
Is that going up to the Intrepid [Sea, Air & Space Museum, New
York City]?
Wilson:
Yes, we’re sending a lot of the leftover materials up there
with them so that they’ll have that to do touch-ups and any
refurbishment work that they might have to do. Hopefully there won’t
be many touch-ups to do once it gets up there.
Ross-Nazzal:
You’ve done a lot of work. Ed had mentioned you guys also found
different tracings of the NASA worm and different paints for the Enterprise
that they painted on originally.
Wilson:
Yes. My recollection was when we sanded down there we weren’t
sure what we were finding. Ed went back and talked to Valerie Neal,
who’s the curator on the Enterprise, and they realized that
what we were finding was one of the first iterations of the NASA worm
logo. We hadn’t realized right off the bat that there was a
couple different renditions of that on the Enterprise. We documented
all that, we took tracings of each of the different variations, then
we left it up to the curator to make the call as far as which version
she wanted us to put back on the Enterprise.
We had a tracing, we’d hold it up, and then we transferred the
tracing onto the Enterprise so we had a penciled outline. Then the
actual application of the “Enterprise” and “NASA”
were all hand-applied. We outlined it in black sign painter’s
paint, and then did an infill on it. We found that the sign painter’s
paint worked the best, although it was too glossy. We couldn’t
find anything that looked quite right, so I ended up using a PPG product
with flattener that we added to it. Painted the whole thing, and we
weren’t quite satisfied with it. The problem with flattened
paints when you paint by hand is that it’s hard to get a real
consistent application. It often looks splotchy, and it did a little
bit. It wasn’t too bad, but we just weren’t satisfied
with it.
After about two weeks of drying we decided to come back and we used
a product called Soluvar that they use a lot for paintings conservation.
It’s a liquid clear coat. We put an application of that over
all the letters, hand-applied, and that gave it a nice consistent
sheen. It really made it look a lot more presentable than what we
initially came up with, something that we thought was really acceptable
once it was done, looked really nice.
Ross-Nazzal:
Are you happy with the paint now that it’s all finished?
Wilson:
Yes, I was actually very surprised at how well it came out. There
are certain areas if you get the lighting just right you can sort
of see the brushstrokes in it, the roller marks. But most of the time
when you’re viewing it I don’t think you’d have
any idea that it was actually roller-applied. I don’t think
the public has got any idea that that’s how we did it.
Ross-Nazzal:
What are your feelings as Enterprise is set to go to New York?
Wilson:
I’m a little sad in a way. It’ll be neat to get the [OV-103]
Discovery, but I think of all the work that we put into the Enterprise.
I’m really proud of all the work we did, and I hate to see it
go. It’s nice to be able to look at it on a regular basis and
think, “We did that.” But it won’t be too far away
so hopefully we’ll be able to visit it up there too.
Ross-Nazzal:
I imagine they’ll be calling on your expertise.
Wilson:
Well, we’re certainly always willing to help. If they need help
with anything, that’s what we’re here for.
Ross-Nazzal:
Rebecca, do you have any questions?
Wright:
I just have one. Is there a special memory that you have of working
on that project?
Wilson:
Probably the most memorable thing was an incident that happened one
of the nights when we were painting. It was pretty late at night,
the whole museum was shut down. Everything was dark except for the
hangar itself where we were working. Oftentimes I would bring a radio
in there, and we’d have the radio playing for background noise.
Usually some classic rock station or something, just to help pass
the time.
Here we are rolling paint, paying attention to what we’re doing,
then all of a sudden we notice down on the floor there’s a SWAT
[special weapons and tactics] team that’s come into the hangar.
Their stance, the way that they’re moving around, they’ve
got weapons in hand, it’s like they’re after somebody.
We’re whispering to each other, “Hey, what’s going
on down here?” Everybody looks, we stop what we’re doing,
“What’s going on? Is there an intruder in here? Why have
we not heard anything?”
After a minute or two a couple of the guys come over right underneath
where we’re painting, and they start whispering up to us. “Hey,
did you see somebody come in here and hide? Did you see anything?”
“No, we didn’t see anything. No, nothing like that.”
Then one of the guys tells us that apparently their sergeant had come
in and had hidden somewhere in the facility, and it was their job
to find her. So here they are cheating, asking us if we knew where
she went. We didn’t. We had no idea where she was at.
It was unusual. It was tense there for a minute or so, because we
thought “What the heck, are we going to have to be evacuated?
What’s going on here?” Then realized it’s just a
drill. Also thought it was kind of odd that nobody told us this was
going on. We thought that if they knew it was planned they would have
given us a heads up that something like that was going to happen.
Wright:
I can imagine being up there with all your paint supplies, thinking
“I’m not leaving this.”
Wilson:
Right, “We’re right in the middle of it, we can’t
stop now.”
Wright:
Did you have any doubt that you’d make that deadline to have
her ready?
Wilson:
I didn’t because I came into the project pretty late. I can
understand why Ed and the other folks did, because it was such a huge
tremendous project and it was four or five people they had on it initially.
It just wasn’t enough people for the scope of what had to be
done. Then I came on board, and it wasn’t very long after I
was there, maybe a week, and another person came out, Bob Weihrauch.
Then a couple weeks after that we got two or three more people.
Once we got everybody going on the project, and everybody was up there
sanding and scraping, it was doable. Before that it was just too much
to do for too few people. Especially, like I talked about, how intensive
it was doing the scraping and how everybody was hurting after a while.
If three or four people had to do all of that, it just would have
killed everybody. Having it spread out to eight or nine people was
a lot more doable than four people.
Wright:
A lot of your work, if I understand correctly, was not just doing
the physical stuff. You were having to analyze where you were at that
piece in time, then scope out what was going to be done a few days
after, and make sure you had the supplies in. Did you do that every
day, or was it just part of an ongoing project? How were you able
to scale this out and make sure all this was done?
Wilson:
We do that a lot actually on the projects that we work on on a normal
basis. Everything we work on ends up being unique and different from
the last project we worked on. You do an initial assessment of the
work you’re going to do—or you think you’re going
to do—what you’re going to need and order those supplies.
Then you get into it.
Oftentimes you find that the method you thought was going to work
the best doesn’t work so good. You have to change gears and
decide what’s a better way of doing this? Oftentimes that means
going to a different type material or a different method. After a
run of three or four days of trying different things and then realizing
this isn’t going to work, then we have to take a step back and
talk, and decide what’s the next logical way to try doing this?
At that point we would decide, and one of us would step out and then
go procure the supplies we needed to do it.
It was challenging because we were working here at Hazy, and everything
else was going on at Garber. Logistically it made it a little bit
challenging to get the materials from Garber out to here, get the
orders from here to Garber, and then get all the paperwork processed
and be able to pick up the supplies and get them from there to here.
But it worked out. Just as you said, you have to plan ahead. I think
we did that pretty good on this project. I don’t think we had
too many work stoppages because of lack of materials.
On the sanding, I didn’t realize how tough the latex paint was.
Here these guys were going at it for a couple weeks nonstop before
I came out and realized, “Okay, I see the problem. This just
isn’t going to work, we’re going to have to go to a coarser
grit.” If we hadn’t stepped up to that it probably would
have taken two or three times as much time to sand it down and get
it prepped with the lighter-weight paper that we were using at the
time.
Wright:
It’s an amazing piece of work.
Ross-Nazzal:
Is there anything you wanted to look at that we didn’t talk
about?
Wilson:
I think I covered most of the paint application, which was the bulk
of what I was involved in. I also worked on the OMS pods back at Garber,
I volunteered for those too. Bob Weihrauch was initially tasked with
doing those, and had worked on them for quite a while by himself.
I think he was feeling a little bit overwhelmed with the whole project.
It came time for the Christmas holidays, and Bob was off for two weeks.
I happened to be there and I decided I’ll jump on this project
with him and give him a hand. I tore the whole back section out of
one of the pods and had it all laid out on the ground, and had it
almost completely replicated by the time that he came back from vacation.
I think he was pretty happy to see that he was going to get a little
bit of help on the project.
It was not a great project, with all the rot and everything in the
wood. I think some of the people didn’t really want to tackle
it, but it was all part of the overall scope of work that needed to
be done. I just didn’t think it was right to have one person
saddled with doing the whole thing by himself. We ended up with about
four people working on the pods after that.
Ross-Nazzal:
Sounds like a big project of its own.
Wilson:
It was, it was a lot of work.
Ross-Nazzal:
Did you have any schematics from NASA in order to rebuild those?
Wilson:
No, nothing. I don’t think there was anything available. I don’t
remember now what the exact history of them was, whether it was actually
NASA that built them or if they had them contracted out, but both
of them were a little bit different. The construction was slightly
different inside, the bracing and such. We tried to replicate as much
as possible the way they had originally done it.
We did make some improvements. We added some additional bracing inside
just to make sure that if there was any rot that we couldn’t
see or couldn’t get to, that they were plenty strong enough
for when we had to hoist them up and put them onto the Shuttle. I
ended up also being part of the team that installed the OMS pods after
they were refurbished, and part of the team that took them off a couple
months ago when we were getting ready for Enterprise to go.
Ross-Nazzal:
A sad moment, bittersweet.
Wilson:
Bittersweet, yes. It’ll be neat to get Discovery in, but it
will be sad to see Enterprise go.
Ross-Nazzal:
Well, we thank you very much for your time this morning.
Wilson:
Oh, you’re welcome.
[End
of interview]
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