URRG

General Rocketry => High Power => Topic started by: mdutch on February 22, 2016, 04:39:47 PM

Title: XXtreme Blue
Post by: mdutch on February 22, 2016, 04:39:47 PM

So here is my next project, I actually started this about four years ago. I guess now is as good as any time to finish it, I'll try to have it ready by URRF 3
 'XXtreme Blue'
 There is all 6" blue tube for the airframe. Starting on the left is the fin can/motor mount. It has 1/2 plywood delta fins mounted thru the wall to a 4" motor mount with an Areo Pac motor retention already assembled. At the top of it you see the BluT coupler, inside it is a section of sliced BluT to make the coupler a double wall construction. The short section to the right is the drogue bay with the altimeter bay in the top of it, the Alt bay will also be Dbl wall const. To the right of that is the Main chute bay along with a pile of cut bulk heads cut out of 3/4" birch plywood. Then to the right again is the conical nose cone,
 the whole rocket will be +/- 12' tall.
 I'll add more detailed photos to our URRG forum as soon as I get started on the project.

FYI; the big tubes, FG nosecone and FG fins you see behind this are a Nike Smoke project that will be a future build sometime in the future. (This is another project I have been collecting parts for since LDRS 31)
Title: Re: XXtreme Blue
Post by: mdutch on February 29, 2016, 01:22:28 PM
Since I wanted a doubled up bulkhead on this the first thing I needed to do was go down to the local rocketry supply center known as Home Depot to get a 'U' bolt that had enough threads to extend out both sides of the bulkhead.
Title: Re: XXtreme Blue
Post by: mdutch on February 29, 2016, 01:24:22 PM
Here are all the parts of the fin can/motor mount coupler assembly.
Title: Re: XXtreme Blue
Post by: mdutch on February 29, 2016, 01:28:30 PM
I first mixed some 15 minute epoxy and added some micro balloons to thicken it so it would stay where I wanted to. This is the interior of the coupler with the bulkhead epoxied into place.
Title: Re: XXtreme Blue
Post by: mdutch on February 29, 2016, 01:31:29 PM
This is the exterior of the coupler with the bulkhead in place. The bulkhead is recessed for a reason that will be explained later.
Title: Re: XXtreme Blue
Post by: RKeller on March 07, 2016, 12:45:00 PM
Lookin good Dutch, what's the reason for the double bulkhead?
Title: Re: XXtreme Blue
Post by: mdutch on March 07, 2016, 02:48:02 PM
Lookin good Dutch, what's the reason for the double bulkhead?

Even though it amounts to over kill I figure that with the total weight of the fin can/motor mount section and the added weight of a 6 Grain 98 mm motor case that there will be no way that the bulk head will fail or the 'U' bolt be able to pull through it when the apogee charge separates the rocket or the main charge brings out the big chute and "jerks" the harness connection point and bulk head.

Besides another Rocketeer once told me that it's best to build your rocket like a "Brick Shit House" because 1. You can always put a big enough motor in it to get it off the pad. and 2. It will survive events that you wouldn't expect it to.
Title: Re: XXtreme Blue
Post by: mdutch on March 09, 2016, 10:47:25 AM
OK, so now the coupler is epoxied into place.

Here you'll also see the altimeter and drogue bays ready for the next step in the build.

What you can't see too well is that on both the interior and exterior of the coupler I poured in enough epoxy to embed the 'U' bolt nuts so they will never come loose.
Title: Re: XXtreme Blue
Post by: mdutch on March 09, 2016, 10:51:41 AM
One last thing I should point out is the pressure relief hole I drilled into the top of the coupler bulk head which will make sliding the 98 mm motor in and out of the fin can sssoooooo much easier.
Title: Re: XXtreme Blue
Post by: mdutch on March 09, 2016, 11:00:24 AM
Here you see the Aeropac motor retainer (sans the screw cap) done so to better view the aft end. Although I did use the screw inserts that come with the retainer you can see that I like to embed the screws in epoxy as well. You can also see that I took two short sections of coupler, cut one to slide into the other, and then epoxied them into the bottom of the fin can to make the end of the tube less susceptible to damage due to hard landings.
Title: Re: XXtreme Blue
Post by: mdutch on March 11, 2016, 02:09:46 PM
Since the whole air frame is blue tube I won't be fiber glassing it, but I do need to fill the spirals before painting it.
The other day I picked up a tube of glazing putty and here you see that I've done the Altimeter Bay and I'm working on the Drogue Bay.
The glazing is easy to use, it dries very fast, and you can easily sand off the excess.

I still have the Main Bay and the Fin Can to do, I also have some saw kerf marks to fill on the fins, but for that I'll use Bondo as they are a bit deeper than the spirals are.
Title: Re: XXtreme Blue
Post by: RKeller on March 11, 2016, 07:48:31 PM
I'm a big fan of bondo spot and glazing putty. I use it for filling mold/parting lines on plastic and fiberglass nosecones too. great stuff!
Title: Re: XXtreme Blue
Post by: mdutch on March 13, 2016, 12:50:41 PM
So I started working on the Altimeter Bay
Here you see the four sections of all thread that are spaced so I can put two of my altimeters in the bay.
I have all of my altimeters mounted to the same type of sled so I can install anyone of them in any of my Alt bays.
(This includes any of my rockets from a 3" air frame up to a 7.5" airframe so far.)
You also see how the 'U' bolts are mounted here. The space between the bulk heads is approximately the distance of the inner sliced coupler which the bulk heads will sit on. There is a lot more I do with this but for now this is ready for the two couplers to be epoxied together.
Title: Re: XXtreme Blue
Post by: mdutch on March 13, 2016, 12:53:32 PM
So here the Altimeter Bay is epoxied together for now. I still have to install the charge contacts and wells yet, and the key switches but I'll show that in detail as I do them.
So for what I did here I first assembled the two couplers and then bolted the bulk heads in place. Then I slid the inner coupler assembly out and prepared my epoxy using US Composites 3 to 1 mix I did a batch large enough to coat the inside of the outer coupler and then used West systems adhesive filleting blend to make part of the epoxy thicker which I spread on the Drogue side of the bay. Then I slid the inner assembly into the bay and set it aside to cure.
Title: Re: XXtreme Blue
Post by: mdutch on March 13, 2016, 12:56:16 PM
Not to start a glue thread here but this is what I like to use for epoxy. I used to use all West System but found US Composite to be of the same quality at half the price. What is nice it that the West filleting blends also work with US C.
The 405 is nice because you can add as much as you like to get any consistency that you need from syrupy to a heavy thick paste.
Actually the 405 can even be used in BSI epoxy but one should note that the thicker you make your mix, the shorter the cure will be.
Title: Re: XXtreme Blue
Post by: mdutch on March 17, 2016, 07:35:02 AM
Now I'm working on the charge connectors, I'm making 4 lead sets for this rocket. Each lead is a length of 26 gauge two lead wire, two connectors soldered on and some shrink tubing. With an 8-32 screw and nut through the connector
Title: Re: XXtreme Blue
Post by: mdutch on March 17, 2016, 07:36:52 AM
Here are the two drogue sets installed in the bottom of the bay.
The interior walls are shiny due to being coated with epoxy.
Title: Re: XXtreme Blue
Post by: mdutch on March 17, 2016, 07:39:57 AM
Here is what it looks like on the exterior of the bay.
Each lead now has a couple flat washers set between two nuts, once you go to install your e-match on the leads you place the stripped end of the lead on the screw post slipped in between the washers and then tighten the top nut. This gives you a good solid through the bulk head connection to your ejection charges with out the possibility of the burnt BP harming your altimeter(s). Also the charge wells are just CPVC pipe caps. I have a 8-32 screw holding each cap thru the bulk head. CPVC is stronger than PVC as it is used for water supply lines. It is not aluminum but it does hold up quite well to several charge events before you need to replace them, and their much less expensive than aluminum too.
Title: Re: XXtreme Blue
Post by: mdutch on March 17, 2016, 07:42:51 AM
You can see the charge wells and lead post here. As this end is towards the main chute bay I'm using bigger charge wells here. The Drogue end has 3/4" caps and the Main end has 1" caps. You can see that I have used the 1" caps once before. They do still have a lot of life left to them so I'm not worried about their integrity as of yet.
Title: Re: XXtreme Blue
Post by: mdutch on March 17, 2016, 07:44:58 AM
While I was at it I also soldered leads onto my key switches seen here.

I like using these barrel switches because they are durable and easy to use and install. Normally you need to drill a 1/2" hole and install them with a back nut. But I have found that if you drill a 7/16" hole you can start them and then use a crescent wrench to finish screwing them in. Of course you have to file a couple flat areas on the outer flange like I did on these to use a crescent wrench.

I will say this method works best with cardboard, phylonic, or thicker air frames. You will probably need to use the 1/2" hole back nut installation on thinner fiberglass airframes for these switches
Title: Re: XXtreme Blue
Post by: Larry Weibert on March 20, 2016, 03:55:40 PM
Great pics Dutch I look forward to seeing that puppy fly. Thanks for the informational tips. You have always offered your knowledge and experience to the rocket community. Thanks for all you have done to help and build the rocket community.
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:09:38 PM
Here are the two switches installed:
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:11:57 PM
As I mentioned before, due to the thickness of the airframe I was able to screw these switches in alleviating the need for the back nut.
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:14:30 PM
So this is one of my sleds that are a standard build that fits most of my altimeters.

This here is one of my Perfectflite MAWD's, the tubes mounted on the sides of the sled are spaced to fit on the all thread that I have mounted in the altimeter bay.

I have most of my Perfectflite MAWD's and Stratologgers mounted on this size sled.
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:16:35 PM
I have been needing to make new sled to fit my MARSA54L altimeters but I still want to be able to use them in most of my rockets.
So this is what I've come up with:
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:20:14 PM
The battery clip is a standard 9volt battery holder
Title: Re: XXtreme Blue
Post by: mdutch on March 22, 2016, 05:22:42 PM
This following photo shows how both altimeters will fit into the altimeter bay.

As you can see here none of the charge wires or switch wires are connected, and neither altimeter is all the way down. But you should be able to get the idea how everything is mounted and attached from this photo.
Title: Re: XXtreme Blue
Post by: mdutch on July 02, 2016, 09:36:34 AM
So I know it was my intention to have this done by URRF 3 but I wasn't able to complete this by then so I guess now that URRF 3 has been an astounding success I guess it's time to begin working on the rocket again.

So we left off with filling the spirals with glazing putty and I have most of the air frame done as shown in this photo of the fin can/motor mount section:
Title: Re: XXtreme Blue
Post by: mdutch on July 02, 2016, 09:42:24 AM
As you can see I have one side and fins done here, I still have the other two sides to do as well as the main chute bay section. Once all the spot putty is done and sanded it will be time to apply primer and make sure I have all the spirals filled to satisfaction. When I'm happy with all of the rocket I will continue with the final painting.
Title: Re: XXtreme Blue
Post by: mdutch on August 06, 2016, 09:20:02 AM
So I'm back at it again, here I finally have the rest of the fin can spot glazed.
Title: Re: XXtreme Blue
Post by: mdutch on February 09, 2019, 07:13:54 PM
Holy Crap, I really need to finish up this build. Let's see, since I just posted it as a BFR for URRF 6 I guess I'm committed, (or committable), I suppose we'll see which.
Title: Re: XXtreme Blue
Post by: PGagnon on March 01, 2019, 07:13:46 PM
Mike

Looks really good.
What motor are you putting it up with?

Paul    8)
Title: Re: XXtreme Blue
Post by: mdutch on March 02, 2019, 07:50:57 AM
Mike

Looks really good.
What motor are you putting it up with?

Paul    8)

'M' class at least, not sure if it will be research or commercial yet.
Title: Re: XXtreme Blue
Post by: PGagnon on March 02, 2019, 12:24:18 PM
 I have this 3 grain M sitting here full of my Blew Bi fuel running at a lower Kn.
Should give a 4+ sec burn with a blue flame.

This will cost you a replacement casting tube and liner. ( 98mm).
I made the motor a couple of years ago and will probably never fly this rocket again.
I can no longer retrieve my rockets with my state of health.

Paul
Title: Re: XXtreme Blue
Post by: mdutch on March 02, 2019, 08:02:37 PM
I'll take you up on that offer, let me check to see what I have in Liner/casting tube sets. If I don't have one in my shop I'll just order one for your motor.

Thanks Paul.
Title: Re: XXtreme Blue
Post by: PGagnon on March 02, 2019, 09:22:42 PM
 This is a True Core case, Same sizes as Loki Research.
24" 3 grain case with a .83 nozzle.
This could be cheaper for you if you only need the fuel.

Paul   8)
Title: Re: XXtreme Blue
Post by: mdutch on March 03, 2019, 07:22:38 AM
Paul I have all the true core 98mm cases and nozzles in 2G to 6G.
Title: Re: XXtreme Blue
Post by: PGagnon on March 03, 2019, 07:42:28 AM
So all you need is the free fuel. Cool.
I need to fill this case with my new fuel ( THOR ) for testing.
This is a pourable fuel with a propep ISP of 189.777 @ 800 psi.
I will be using this in my booster for the space shot.

Paul
Title: Re: XXtreme Blue
Post by: mdutch on March 03, 2019, 06:02:41 PM
Cool, I still owe you something.
Title: Re: XXtreme Blue
Post by: PGagnon on March 03, 2019, 06:39:17 PM



                                                                            $350.00


  I have casting tube.

Paul
Title: Re: XXtreme Blue
Post by: mdutch on March 04, 2019, 07:58:50 AM
                                                            yep                                           
Title: Re: XXtreme Blue
Post by: PGagnon on March 04, 2019, 08:19:22 PM
 I got casting tube, You got liner ? I can use the liner that I have.   ::)

The nozzle I was going to use was 0.813 .