The photo below represents what the airframe will look like with the engine cowling attached. The 4-inch version will not have the same engine nozzle as the full-size version because we want to be able to stuff at least a 29mm motor mount in the smaller rocket. The cowling in the photoshopped photo is the equivalent of a 38mm tube; we expect we may need to eject the motor mount when the 4-inch SS1 converts to glide mode.
You may be curious about why Rick and Dave made a pointed boat tail since it just needs to be trimmed off anyway. This was intentional because it makes the molds more versatile. Depending on how much Brad enjoys replicating these 4-inch cones, below is a representation of how they can be used to make various bulbous rockets.
The cone plugs have been prepped and painted prior to
making the molds.
No significance to the white paint.
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The melamine flanges are attached to create separation of
the mold halves.
Then the release agents are applied.
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The airfoil plug. It was cut from foam with a hot wire cutter and covered with 1/4oz fiberglass.
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It was made a a single piece purely out of convenience. The castings will be trimmed apart after molding.
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Brad's Yellow Lab, Mike. He was curious why Brad was taking photos, and hoped that the airfoil was made of bacon.
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The melamine flanges are attached to create separation of
the mold halves.
Then the release agents are applied.
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The plugs and flanges covered with fiberglass.
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The finished molds and the original plugs.
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Fiberglass cones fresh from the molds
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The tailcone is trimmed for the motor tube
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Cradle to align the airfoils during mounting
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The airfoils are trimmed and mated to airframe
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The booms are cut from 1/8" honeycomb nomex
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As are the elevons. This material is very strong.
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The underside of the airframe and the boom assemblies.
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Top view of the SS1 with the booms attached.
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Standing upright. The knife is there to provide scale.
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Zoom, zoom, zoom.
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