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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:07 Titel: |
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[SIZE="4"]Command Module (CM) Plug[/SIZE]
I'll make the CM a 2 pieces fiberglass entity thus requiring 2 different molds: the conical section and the heatshield one.
I started with the conical plug, being it the biggest one.
I designed a lite-ply frame and I cut the required pieces on my own: the largest (base) ring spans something more than 24" but it is still Dremel cut-table!!!
The templates were transferred to the wood...
... and cut:
It was still possible to cut the inner 4" dia hole with the Dremel!
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:07 Titel: |
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The twelve stringers followed...
... and the assembly began around a 4" airframe core section:
The very first overall impression:
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:08 Titel: |
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In the meanwhile I put the parting board together (thick MDF):
I added small MDF blocks to the CM frame to better support the joining screws:
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:08 Titel: |
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Skinning the frame required some thought. I started by sanding the frame smooth:
Then I rolled it over 2 layers of cloth to mark the skin outline:
Next I laminated those 2 layers on a flat surface:
Finally the skin was applied to the frame using Gorilla Glue (whose foaming action fills most of the voids):
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:08 Titel: |
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The tip was added (again it consists of a balsa-filled ply frame)...
... it was sanded to shape...
... and finally glassed:
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:09 Titel: |
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While I was filling some of the defects...
... I felt the plug needed some more stiffness so I went with 2 more external layers of cloth:
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:09 Titel: |
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Then it came the mandatory yet boring fill'n'sand part of the business:
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:09 Titel: |
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Just a few days before Christmas I had the chance to give it the very first primer coats!
I started with a paint-promoter coat...
... followed by the primer:
_________________ Giacomo 'g_boxwood' Bosso
TRA#9986 L2 |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: So 08 Feb 2009, 12:10 Titel: |
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[SIZE="4"]Heatshield Plug[/SIZE]
Before finishing the conical section plug I need to put together the heatshield plug to match them precisely!
I spent a little time in front of the PC to figure out how to model the curvature of the heatshield. I came out with the following solution based on lite-ply framing and foam.
Notched base ring with 29 mm core:
Vertical frames and interlocking diagonal plates:
Raw foam blocks:
_________________ Giacomo 'g_boxwood' Bosso
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Tom Engelhardt
Anmeldungsdatum: 05.08.2005 Beiträge: 318 Wohnort: Göttingen
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Verfasst am: So 08 Feb 2009, 13:48 Titel: |
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Giacomo,
that is outstanding, both design and craftmanship!!!! Well done!
You have to bring this to ALRS, it will most certainly be quite a show!!!
Tom
_________________ Science flies you to the Moon.
Religion flies you into buildings. |
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Juerg Site Admin
Anmeldungsdatum: 27.02.2005 Beiträge: 4545 Wohnort: Oberengstringen
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Rolli
Anmeldungsdatum: 07.03.2005 Beiträge: 666 Wohnort: D-38820 Halberstadt
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Verfasst am: So 08 Feb 2009, 23:17 Titel: |
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alle Achtung, sowas von scale! Boah, bin begeistert und neidisch zugleich... ein ganz großes Kompliment!
Grüße Rolli
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MikeHB
Anmeldungsdatum: 16.07.2005 Beiträge: 157 Wohnort: Bremen
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Verfasst am: Mo 09 Feb 2009, 0:03 Titel: |
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I am deeply impressed! Wonderful to see the gold old technique of Apollo rising again, right on time for the 40th anniversary of Apollo 11th epic journey to the moon.
Keep on going!
Michael
_________________ Sagt Abraham zu Bebraham: Kann ich mal Dein Cebra ham? |
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Mo 09 Feb 2009, 10:26 Titel: |
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Thank you all!
I was a bit worried about it due to the unusual design and cluster requirements.
Do you think the rod setup will be adequate?
_________________ Giacomo 'g_boxwood' Bosso
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