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Louis
Anmeldungsdatum: 19.02.2007 Beiträge: 765 Wohnort: Zeven
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Verfasst am: Fr 24 Apr 2009, 11:22 Titel: |
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Ouch! You destroyed the thing, your wife probably thought that you need doctor assistance
Good luck laminating the cone.
Louis
_________________ Always keep the pointy side up!
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Juerg Site Admin
Anmeldungsdatum: 27.02.2005 Beiträge: 4545 Wohnort: Oberengstringen
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Louis
Anmeldungsdatum: 19.02.2007 Beiträge: 765 Wohnort: Zeven
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Verfasst am: Fr 01 Mai 2009, 15:44 Titel: |
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Very nice!
One thing I do not understand: If you make a mold, why don't you use it to make a lighter model instead of using the original model?
Louis
_________________ Always keep the pointy side up!
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Mo 04 Mai 2009, 8:56 Titel: |
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Louis, you're right!
I'll make those parts right out of the mold later on!
The plugs are so big that I want to put them to use instead of having them laying around the workshop with any meaning at all.
The project requires more than one capsule as I won't test everything during the first flight: the plugs are the non-functional capsule, with no internals and no functionality; it won't separate from the tower and it won't come down under its own chutes.
Thank you for pointing out!
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Sa 16 Mai 2009, 10:31 Titel: |
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g_boxwood hat folgendes geschrieben: | Now, that is too flimsy to fly, I'll add some glass from the inside before joining it to the CM. The final weight will increase but I already saved a lot! |
Ok, I left you with the flimsy heatshield: it went from 2560 grams down to 635 and it turned out even lighter (570 grams) as I spent some more time sanding off the excess resin here and there.
Now, it is flimsy because I covered it with a SINGLE layer of heavy cloth: The capsule got 4 layers and it survived a brutal de-molding!
So I added 2 internal layers of 200 gr/mq fiberglass cloth in the form of overlapping triangles between the wooden spiderweb:
I also drilled a lot of perimetral holes along the remainings of the base ring to promote epoxy adhesion:
As you can see the final weight rose to 826 grams which sounds like an acceptable trade-off in the end.
I also got the capsule interiors ready for joining: a lite-ply ring was added and drilled, I cleaned the skin from glue residues and I trimmed the forward wooden frame I left as much as possible:
The capsule and the heatshield are now permanently and happily joined together to form the first flying capsule in the program!
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Sa 16 Mai 2009, 10:32 Titel: |
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Now the capsule isn't finished yet but I need to move onto other working areas prior to its completion.
Remember the Booster Skirt Mold?
I got the first skirt...
... raw out of the mold...
... and trimmed (view from the inside):
The openings are for the 4 launch lugs and for the 2 sets of external wire channels:
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Sa 16 Mai 2009, 10:32 Titel: |
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got back to the booster section...
... and I added the skirt base-plate (1/4" lite-ply) and the fillets:
Launch lug openings are next...
... as well as the launch lugs themselves with hefty fillets:
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Sa 16 Mai 2009, 10:33 Titel: |
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Booster Protective Cover
That's all is missing to complete the booster section!
Using the capsule plug I laminated a sandwich of
. 1 layer of heavy f/g cloth
. 1 layer of 1/8" thick absorber
. another layer of heavy cloth
to obtain a very raw-looking BPC:
The absober choice is stupid: not only it adds unwanted weight but it also leads to a weird finish!!!
The de-molded BPC...
... trimmed:
_________________ Giacomo 'g_boxwood' Bosso
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g_boxwood
Anmeldungsdatum: 08.06.2006 Beiträge: 172
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Verfasst am: Sa 16 Mai 2009, 10:35 Titel: |
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Some sort of 'seat' for the airframe tubing is routed on the exterior of the BPC...
... so that the entire airframe can be joined checking for the correct alignment between each section:
The epoxy joint isn't enough: an external reinforcement is required in the form of overlapping fiberglass strips; I also added an extra skin layer (light cloth) for a better finish...
Two coats of 2-pack automotive (yet lightweight) filler were added...
_________________ Giacomo 'g_boxwood' Bosso
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