The German Corrugated Iron Shelter: Part II
Der Deutsche Wellblechunterstand

The Reconstruction Project

The first challenge in recreating the shelter was to gain the ability to speak the "technical" language of those people that might complete the project. As the author is a pencil-pusher by day, not a mechanical engineer, he does not have a manufacturing background. Therefore, Part I, with all its photographs, was created and posted to this website so that he could graphically show the details to possible manufacturers.

The second challenge was to find manufacturers who could source the materials needed to take on a relatively small project like this. The search began with a listing of metal fabricators and distributors on an industrial business-to-business website: www.thebluebook.com.

Calls were placed to many of these firms. However, most firms contacted did not think they would be able to help. The biggest problem appeared to be sourcing the appropriate steel panels: the triple combination of corrugation, curve and approximate size was not easy.

This problem was overcome with a helpful comment from one fabricator, who suggested that he examine the steel used by silo manufacturers. Armed with the internet, the search focused on this potential source, and the author found an Indiana-based manufacturer that assembled silos that were 9' in diameter, where each "ring" of the silo was constructed from three steel panels. The panel length, 118.5", was quite close to the originals, even though the panels were narrower, at 33.5". More important, the curve of the panels--120 degrees of a 360 degree circle--was close to perfect. The only problem with the panels was the shallow corrugation--about 0.5" from hill to valley--relative to the German originals, which had a corrugation depth of about 2.75" from hill to valley. The search for the perfect panel continued for another week, but no panels could be found that matched all three characteristics: corrugation, curve and size. Therefore, the decision was made to order ten steel panels from Brock Manufacturing in Milford, Indiana.

The next step was to find a metal fabricator who could prepare and attach the C-channels to the panels. With the help of a neighbor, one was located not too far from the author's house in New Jersey. It was agreed that the panels would be shipped to Dunphey & Associates Supply Co., Inc. (aka DASCO) in Whippany, New Jersey for final assembly.

As with the steel panels, the project team could not find a C-channel that matched the originals 100%, but the C-channels currently on the market came close. The next problem was the rivets. DASCO could not the right size of rivets to attach the C-channels to the panels. The author and members of his reenacting unit put their heads together and instructed DASCO to use another period construction method: flat, slotted screws and square--not modern octagonal--nuts.

On Friday, March 12, 2004 the completed panels were delivered to the author's house in Gillette, New Jersey. This date was a little more than six months after the author returned from his research trip to France. More important, the delivery date was eight days before the living history time-line competition entitled Military Through the Ages and held in Jamestown, Virginia.

Six months and about $2,300 later the author took delivery of a shelter that is very similar in design, construction, and size to the originals built by the Imperial German Army 90 years ago in France. Without burying it into a hillside, the shelter provides a unique and somewhat mobile display for living history events. It is only "somewhat mobile," as each of the ten panels weighs 120 pounds before adding the C-channels and hardware. Thus, it needs about four to six strong individuals to assemble.

The author and his reenacting unit wishes to thank the individuals at Brock Manufacturing (especially Alan Schlagenhauf), Northeast Agri Systems (Brock's sales representative in Lititz, PA), Frank Smith, and DASCO for their assistance in completing this project!

Photographs of the Finished Product:

The photographs below were taken at the March 2004 Military Through the Ages Living History Timeline held in Jamestown Virginia. The shelter was first assembled for this event.

Shelter Available for use by Other Reenacting Units:

This shelter is available for use by other WWI reenacting or history units. It is most appropriate for German or American units who are using captured German positions. The author has not studied the French or British shelters. If interested, please contact Randal Gaulke at lavarennes@patmedia.net to discuss the details. To see this article in the original form please look at: http://www.meuse-argonne.com