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Author Topic: Terra Australis - Build  (Read 15593 times)
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EMiR
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« Reply #14 on: October 30, 2011, 08:53:50 PM »

Got the boat tail done today

it machined up quiet nice









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EMiR
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« Reply #15 on: November 01, 2011, 07:23:24 PM »

ok, I had a few little set backs,

the motor bridle system wouldn't fit in the body tube, so I machined slots in the sleeve,
only to find out that the sleeve was nothing more than thin aluminum sheet glued on with conact glue.

I got conformation from HyperTEK, that the sleeve is not structual, and not to retain on it ether.


So I removed it altogether, and wrapped a carbon sleeve on, and adheared it to the tank wth JB weld, and embedded kevlar cord.

the platted cords come from 2 x 3600lb Kevlar ropes laid one inside the other, broken down into 8 Plats, the emmbeded in the carbon leeve
(hand platted the 8 plats, took awhile as you could imagine)




Body tube slids on  like a glove




Also I wasn't happy with the way the fins came out, try to put the Airfoil in them, proved to be quite a chalenge
plus I didn't like the profile I chose.
So I'm starting again, this Time I'm using 1.5mm Birch plywood sheets, with 5 layer of carbon between.



I will hand bevel the airfoil this time, using a rasp and sandpaper.
and the airfoil Profile is slightly different
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EMiR
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« Reply #16 on: November 01, 2011, 07:32:09 PM »

Got the AV/Bay and lower tube joiner done today

The Avbay is made up of 6 Layers of 2x2 Twill, and the Lower Joiner is made up of 4 layers of 2x2 twill.

Left; AVbay Left
Right; Lower Tube Joiner



AVBay, showing the step down edges for the bulk heads


I am going over to John's tomorrow to turn up the Alloy Bulk heads for the AV Bay, and the Alloy Collar (Outer Joiner Ring)
and the Alloy Nose Cone tip
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EMiR
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« Reply #17 on: November 01, 2011, 07:50:52 PM »

Although I had a little set back, I'm still on track time wise.
I will have the Fins on and finished by Friday.
Av/Bay done by then also. and nose cone finished.

Sanded and ready for final coats of paint and clear coats, by the week end.

Electronics I will do early next week, and I should be ready for the ejections tests by Tuesday at this stage.


Also I am currently painting my Little John rocket,

Finishing the Carbon fibre G-Force, 4 cluster 29mm
this will be the 3 AP boost, with an airstarted H70 Hybrid central motor.

And rebuilding the HyperLoc 300 - Which is now called Hyper Australis

AND.... finsh prepairing the 3" CF Alien for it maiden flight


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wolflair
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« Reply #18 on: November 02, 2011, 10:27:19 PM »

nice tailcone Ash

take your time check and recheck each component as you go along she is looking good so far  blcool blcool
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EMiR
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« Reply #19 on: November 02, 2011, 11:48:48 PM »

thanks mate,

I can tell you, I've more than double checked every thing.  blhuh

I've been pulling 16-18hr days to get this finshed by friday, glad I'm nearly finished.

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EMiR
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« Reply #20 on: November 03, 2011, 12:01:04 AM »

Today was a bit of a waste, as I spent most of the day down the gold coast, stuffing around with the trailer and not getting a whole lot done.

bit I did get the rest of the bits machined up later in the day/night

AV/Bay bulk heads
AV/Bay Join Collar
and Nose cone tip




And got the fins cut out (Cough.... again.....)

The template on top shows the profile I'm going for this time..     A little easier than the last profile I tried...

Also the Carbon and play lay-up was so much more even (Flat) than the last lay-up I did.
and these new fins are 2mm thinner, so I'm hoping that might give me another 500-1000' alt


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EMiR
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« Reply #21 on: November 03, 2011, 10:21:37 PM »





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hotspot
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« Reply #22 on: November 03, 2011, 10:50:46 PM »

Fantastic build wish I had the time to scratch build my rockets.
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EMiR
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« Reply #23 on: November 05, 2011, 09:12:51 AM »

Thanks HotSpot..

Wish I had time to do it aswell...  blwink

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EMiR
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« Reply #24 on: November 05, 2011, 09:46:13 AM »

Big build day yesterday, got a lot done....


Finished Shaping the fins









I love the look of the layered plywood, and I was half tempted to leave the wood exposed, and just epoxy finish the wood.

I'm thinking of doing a fin set like this on another rocket project, with the nice wood finish.

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EMiR
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« Reply #25 on: November 05, 2011, 10:02:51 AM »

his a good friend of mine, Mike, DragonFlight on the these forums.

Helping out with some of the prep work on the body tubes...





Ok so your face wasn't as black as mine  blgrin


Tube before it's first polish coat..



then after.



it's looking pretty sweet... this tube is the mid section.


While Mike was busying rubbing black carbon all over his face...
I finished getting the fins laid-up with the 4 outer layers of carbon (2 plain weave and 2 twill)

the outer layer were laid on, then compressed in between dense foam layers and wood back boards.
as you can see if gave a as good, if not better finish than vac bagging.
 


Fin lay up is extremely strong,  can not flex the fin by hand in any direction.


Total Layup (sandwich) was in this order;

Layer 01. 0 / 90 - 2x2 Twill
Layer 02. 0 / 90 - 1x1 Plain Weave

Layer 03. 45 / 90 / 45 - Birch 1.5mm Ply Wood

Layer 04. 45 / -45 - 2x2 Twill
Layer 05. 45 - 3K Uni Directional

Layer 06. 0 / 90 - 2x2 Twill

Layer 07. -45 - 3K Uni Directional
Layer 08. 45 / -45 - 2x2 Twill

Layer 09. 45 / 90 / 45 - Birch 1.5mm Ply Wood

Layer 10. 0 / 90 - 1x1 Plain Weave
Layer 11. 0 / 90 - 2x2 Twill

Total thickness ~5mm


I did start to sand the fins also, and the leading and trailing edge have come up like razor edges.

Pics soon..
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EMiR
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« Reply #26 on: November 06, 2011, 08:32:52 AM »

I was absolutely bugged yesterday, having to work and a late night before, and only getting 3hrs sleep.

I decided last night that I couldn't be bothered to get all black and stuff, I thought I'd give the tube and fin sanding a miss.

and went with the more clean option of tiding up the AV/Bay.








I got a end on the 3600lb Kevlar Recovery harness done, here I've used an inserted compression method rather than re-splice
which apparently is stronger than the rope it self.



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EMiR
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« Reply #27 on: November 06, 2011, 07:06:06 PM »

got all the ends of tubes squared up this afternoon, as well as cleaned up the nose cone sholder,

First complete fit test.




Just got the fin fillets and painting to go in the next day or so.

and then finish the painting... and clear coats..

plus the electronics and video camera bays
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