Background During the mid 1930s,
Generalleutnant Walther Wever, a longtime advocate of
strategic bombing, pressed the
Luftwaffe to develop a dedicated long-range bomber for the role of attacking the
Soviet Union's factories in the
Ural Mountain area. This concept was received with significant skepticism amongst many senior officials within the
Luftwaffe and, by 1936, this "
Ural bomber" program had delivered two rather uninspiring designs, the
Dornier Do 19 and
Junkers Ju 89. Wever continued to press for new designs for this role, and the
Reichsluftfahrtministerium (RLM) finally released a new specification for what they called Bomber A on 3 June 1936. This called for a significantly more advanced design with higher speeds, longer range and larger payloads. This was also the same day that Wever was killed in an air crash, and the design lost its only politically powerful champion. Heinkel Flugzeugwerke's estimated performance figures for
Projekt 1041 included a top speed of 550 km/h (342 mph) at 5,500 m (18,050 ft) and a loaded weight of 27,000 kg (59,500 lb). In order to achieve these estimates,
Ernst Heinkel's chief designer,
Siegfried Günter, employed several revolutionary features. The outer sides of each of the component engines' crankcases were connected to the nacelle firewall through forged mountings similar to what would be used for either a single DB 601 or DB 605 engine-powered aircraft installation. When combined with the central space-frame mount designed especially for the "power system" format, this resulted in a Daimler-Benz "coupled" twin-crankcase "power system" having a trio of engine mount structures within its nacelle accommodation. The starboard DB 601 component engine had to be fitted with a mirror-image version of its mechanically driven centrifugal supercharger, drawing air from the starboard side of the engine. Two of the DB 606s, each of which initially developed 2,600 PS (2,564 hp, 1,912 kW) for take-off and weighing some 1,515 kg (3,340 lb) apiece, were to power the He 177. The DB 606 — and its eventual replacement, the
Daimler-Benz DB 605-based "DB 610" — were to be the only two production German aviation powerplants designed to surpass 2,040 PS (2,010 hp, 1,500 kW) of power, something that the Germans had
considerable challenges in developing during the war into production-ready, combat-reliable aviation engines.
Surface evaporation cooling For aerodynamic cleanliness, Günter intended to dispense with the usual system of drag-producing engine
radiators and planned on using a surface
evaporative cooling system instead. Such surface cooling, in the form of simpler surface radiators, had been used on
British high-speed racing seaplanes as early as 1929. This sort of system was pioneered on the eight examples built of the Heinkel He 119 high-speed reconnaissance aircraft prototype series, already flying with the twin-crankcase DB 606 "power system" engine with success from the beginning, and was also intended for use on the
He 100 high-speed fighter prototypes. The coolant water is pressurized, raising its boiling point, in this case to about 110 °C (230 °F). As the superheated water leaves the engine it enters an expansion area where the pressure drops and the water flashes to steam. The steam is then cooled by running it in pipes along the outer skin of the fuselage and wings. Before the design of the He 177 was finalized, it was clear that such a system would be incapable of dealing with the vast amount of heat generated by each of the twinned DB 601-based powerplants, forcing the abandonment of the idea of using evaporative cooling systems, in favour of conventional annular radiators fitted directly behind each propeller. These resembled, but were larger in capacity, than those fitted to the
Junkers Ju 88 A bomber, and added to the He 177's weight and drag.
Defensive armament and bulged upper glazing for upright gunner's seating. Günter's original intention had been to equip the He 177 with three cockpit-controlled remote gun turrets, with two of them to come from the
Junkers Ju 288 program, leaving one manned emplacement in the tail. Compared with the manned position, a remotely controlled, turreted defensive armament emplacement system traded technical complexity for reduction of size, weight and drag; it had the advantage that the gunner could be placed in a protected position, with the best possible view and with less risk of being blinded by the flash from his own guns. Although work on remotely controlled aircraft defensive systems had reached a relatively advanced stage in Germany in the late 1930s, progress in this field within Germany's aviation and armaments systems engineers and manufacturers was to prove insufficient to keep pace with the He 177. As a result, the He 177 had to be modified to accommodate larger and heavier manned positions, such as the manned rear dorsal turret usually fitted to almost all examples of the
Greif, armed with a 13 mm
MG 131 machine gun. That installation meant that the fuselage had to receive structural strengthening in several locations. Most of the later production aircraft did receive a remote forward dorsal turret, the
Fernbedienbare Drehlafette (translated as "Remotely operated rotating gun-mount" and abbreviated "FDL") 131Z, armed with two MG 131 machine guns, located at a point on the fuselage directly above the
wing root's leading-edge, with its
rotating hemispherical sighting station dome located a short distance forward of the turret and slightly offset to starboard, just behind the forward cabin area. A compact tail gun position was fitted for rearward defense, armed with one MG 131 machine gun but its streamlined glazing meant that the gunner lay prone, severely restricting his comfort on long missions. A revised tail gun position with a bulged upper glazing was fitted to the He 177A-3 and later models, which permitted the gunner to sit upright. The revised design required a reduction of the lower end of the
rudder surface for clearance. The MG 131 gun would often be replaced with a 20 mm
MG 151 cannon or in a few instances, a semi-experimental twin MG 131Z mount, with the twinned 13 mm calibre guns mounted one above the other, at the rear of the standard bulged upper glazing emplacement. Usually, a 7.92 mm
MG 81 machine gun in a flexible mount was positioned in the upper starboard side of the cockpit nose glazing for defense against frontal attacks. The undernose, inverted-
casemate Bola gondola (a common ventral armament fitment on many German bombers), which was the full width of the fuselage where it emerged from under the nose and centered under the forward cabin, usually had a flexibly mounted, drum-fed 20 mm
MG FF cannon at the front end as added forward defense and a flexibly mounted MG 81 machine gun in the rear, for the initial He 177A-1. An MG 151 cannon replaced the forward MG FF cannon in later production models, with an MG 131 usually replacing the MG 81, for rearwards ventral defense.
Wing The He 177 had Fowler-type extensible
trailing edge flaps, which covered the trailing edge of the wing, including those portions covered by
ailerons. Each aileron comprised upper and lower portions, the latter arranged to slide rearwards with flap extension, while the upper part retained its function of providing lateral control for take-off and landing. The original wing design did not fully take into account the stresses resulting from the operation of the Fowler flaps. A
Rechlin report dated 9 October 1942 stated: "The examination has shown that the strength of the He 177's wings is one-third below that estimated by Heinkel. The reason for this is the uneven rigidity of the individual members with consequent deformation under load. This condition was not recognized by Heinkel at the proper time, the failure tests having been undertaken too late in view of the size of the structure." Tests on the 40th production A-1 aircraft in September 1942, revealed serious outer wing panel component damage after only some 20 flights, due to the aerodynamic stress from diving attack exercises. Costly and extensive strengthening was needed to solve the problem, which significantly increased the aircraft's weight. Starting with the later versions of the He 177A-3, the Fowler flaps along the outboard wing sections were no longer fitted and a strengthened wing design was introduced on the He 177A-5.
Dive bombing The inaccuracy of horizontal bombing during the Ural bomber program demonstrated weaknesses in German
bombsights and created doubts about the effectiveness of level bombing of factories. While Wever had been advocating the Ural Bomber concept, others in the
Luftwaffe were growing increasingly interested in
dive bombing. and
Hermann Göring's rescinding of the dive-attack requirement on 15 September 1942, the barred-gate type dive brakes on the wing's lower surfaces, placed just forward of each of the outboard ends of the Fowler flap panels, were omitted from all He 177A built after the initial A-0 pre-production batch. A photo of one of the 12 "destroyer" He 177A-1/U2, heavy-cannon-armed test airframes, showed the retracted dive brake panel still fitted on the undersurface of the outer starboard wing.
Undercarriage During development, the anticipated weight of the He 177 increased so much that a main
undercarriage design sufficient to handle the loaded weight, was difficult to achieve. The engine nacelles and wings had little room for the main undercarriage members, which needed to be longer than usual, for ground clearance for the large diameter four-blade
counter-rotating propellers. After several extremely complex arrangements had been considered during initial design, a novel system was adopted. Instead of a wheel leg under each engine nacelle, two-wheel legs were attached to the main spar at each nacelle, the outboard legs retracting upward and outward into shallow wing wells and the inboard legs swinging upward and inward into similar wells in the wing roots, with all units enclosed by flush fitting wheel and strut doors, which almost met under each engine nacelle when fully extended. During the retraction cycle, the forward-oriented lever-action lower gear strut sections (onto which the wheels were mounted on their axles), pivoted backwards to a 90° angle from 120° when fully extended. This was in order to position the wheels to fit into the wheel wells during the sideways folding action. A conventional rearwards-retracting single-leg twin wheel arrangement for each main gear, a design heavily influenced by the He 219's similar main gear components, was used on the two prototypes built (one during the war, one post-war) of the
He 274 in France. Drawings were made for a
tricycle gear arrangement for the four-BMW 801E radial-engine powered
Amerikabomber entry version of the proposed He 277 by February 1943, which was also depicted with single main gear struts with twin wheels. For the He 177A's own landing gear maintenance needs, some two hours were required just to change a main gear tire, using special Heinkel-designed capacity main gear jacks and blocks. ==Prototypes==