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No redesign necessary. If the Mosquito is to be manufactured in Canada then it should be designed for aluminum construction from the beginning.
An aluminium Mossie would have been heavier .
It may just be the DeHaviland marketing department and who are they to make this claim as their knowledge of equivalent aluminium structures was apparently quite poor (eg Commet fatique crashes).
moving all DeHavilland to Canada sounds alittle far fetched but please recall that from 45 on Canada did become a major player in aircraft design and manufacture starting with Chipmunk, Beaver Otter Canadair Jetliner and CF100, Northstar the DC4 or 6 Hyrbrid with Merlins, the Jetliner was dropped as to pick up the manufacture of Sabres for MAP
The American government on the other hand did pay for large numbers of new factories. Once the contracts were complete however the plants and machinery belong to the US government, not the companies that ran the plants for the government.
At the end of the war their may have been a few ( or more than A few) sweetheart deals on buildings and machinery declared surplus. In other cases the factories were shuttered only to be reopened during the Korean war.
No redesign necessary. If the Mosquito is to be manufactured in Canada then it should be designed for aluminum construction from the beginning.
Had designed the basic trainers Fleet Fawn and Finch , the still working and flying Norseman most of the design work went in trainers in 39 40 , but pays to recall that of all nations on earth I can't think of any other that has been more influenced by aviation, the area in the north was a total unknown for the most part in comes the Bushpilot with no accurate maps and horrible navigation problems between true and magnetic north compounded by the seasons from floats to skis to wheels , and the fact of Canadian sucess as far as pilots in WW1 certainly helped foster its growth.What aircraft design and construction capabilities did Canada have in the period 1939-1940? Remembering that the Mosquito was designed and constructed in that period and the prototype W4050 first flew in late November 1940?
Could de Havilland Canada have matched that? Somehow I doubt it.
If you think Canada's aviation industry could have been better utilised, I suggest that an aluminium Mosquito was not the best plan. However, an all-aluminium alternative could have been made. Perhaps Hawkers get the go-ahead to develop the P.1005 high speed bomber project in Canada.
The go-ahead would have been given, probably, late 1941, so a prototype could have been flying by late 1942/early 1943.
As the Sabre was a) still very troublesome at this time and b) not available in a high altitude version perhaps alterantive engines could have been arranged. I'd suggest an Allison V-3420 as being a potential replacement, either with a 2 stage supercharger or a turbocharged installation. I'd still continue with a Sabre prototype on the off-chance that they get sorted (which they did) and built in sufficient numbers.