spaceman Posted March 13, 2023 Author Share Posted March 13, 2023 Hello everybody, well, the smaller the details to be scratched, the closer you have to look to see their shape and being able to determine the needed dimensions. As you can see in this image section, the Holder sockets are in the form of small U-profiles in which the handrails are articulated. Source: forum.nasaspaceflight.com (STS-9, Ares67) Since this photo shows the canister used during STS-9 (11/1983), it can be assumed that these Handrails and Ladders already existed at the time of STS-6 (04/1983), but unfortunately I don't have any direct photos of it. On the following photos of the Launch pad during STS-6 it looks like this, Source: retrospaceimages.com (STS-6) because you can see the holder sockets at least with high magnification, like here atop of the canister hanging in the RSS-Payload Bay, and here during the exit from the Vertical Processing Facility (VPF). Source: retrospaceimages.com (STS-6) In this drawing I've finally determined the dimensions of the holders. Source: James MacLaren, Page 52 And as you can plainly see, they are indeed tiny and, according to my previous idea, should each consist of four parts, which is why for 18 holders only 72 snippets would be needed. Well that can still be going funny. Quote Link to post Share on other sites
CaptKirk Posted March 14, 2023 Share Posted March 14, 2023 Hi Manfred. I must have missed your previous idea because I'm not clear why each is four parts? Could each bracket not be made from a small section of U-shaped channel? I assume (probably incorrectly) that you don't intend to have working pivot pins - but if you did, that would still only be 4 parts per rail section? Quote Link to post Share on other sites
spaceman Posted March 14, 2023 Author Share Posted March 14, 2023 Hi Kirk, thanks for your tip and that you have ruminated about it and want help me. I've immediately thought of my narrowest Evergreen profiles too, but both the H and U shapes are 1,5 mm wide, which doesn't match the delicate Handrails. Then I took a Channel profile which is 1,3 mm wide and compared it with my version (right) which is 0,9 mm wide, using 0,2 mm thick strips for the sides, which looks like this. I think if I would cut a strip (0,13 mm x 0,75 mm) for the sides it should look still a little bit better, still closer to the real size determined in the drawing, although it's more effort. Quote Link to post Share on other sites
CaptKirk Posted March 15, 2023 Share Posted March 15, 2023 Even with the help of your giant 1 cent (😁) and the scale on your cutting mat, I often forget just how tiny all these pieces are. At the moment, my head is in 1:24 world, so please ignore any stupid suggestions I make!! Quote Link to post Share on other sites
spaceman Posted March 15, 2023 Author Share Posted March 15, 2023 No problem Kirk, 1:160 is a little bit smaller, if you want so from the Underworld. The dimensions determined from the NASA drawing are decisive, whereby the blue dimension (diameter of the handrails) is my reference dimension. BTW, please ignore the blue 12, it comes only from copy and paste. Quote Link to post Share on other sites
spaceman Posted March 17, 2023 Author Share Posted March 17, 2023 Hello everybody, originally I had immediately thought of my narrowest Evergreen profiles, but both the H profiles and the U profiles are 1,5 mm wide, which would not match to the filigree handrails. Then I've compared a Channel profile (1,3 mm) with my planned four-part variant (right), which, when using strips (0,2 mm x 0,75 mm) for the sides, is approx. 0,9 mm wide, which looks more pleasing in combination with the round rod (Ø 0,45 mm) of the handrail struts. And if I would cut a Styrene strip (0,13mm x 0,75mm) for the sides, it should look even better and even closer to the size specified in the NASA drawing get there, what would mean a bit more effort. So I've tried to scratch such a Prototype. But it's already not easy to cut a 0,75 mm wide strip, but which I managed to do. I then placed this strip upright on the ruler angle, clamped the Base strip (0,25 mm x 0,5 mm) in front of it and then both strips were carefully glued by using MEK at their connecting line. Then I glued a small strip onto the other side, and let it dry. Then I've carefully cut off a 1 mm long part from this U profile with a razor blade, which actually succeeded with the precautionary placed Jump away-Protection tape (left). Now only the small end piece had to be glued and trimmed, whereupon the test fitting of the first Mount on the handrail could take place. Although the feasibility of the Prototype could be shown in principle, I have in mind a smarter solution for scratching of the remaining 17 mounts, by what the effort should let be reduce. Quote Link to post Share on other sites
spaceman Posted March 18, 2023 Author Share Posted March 18, 2023 (edited) Hello everybody, is there anybody in there? And thus to this new variant for the production of the Handrail brackets that I have been thinking about. The idea behind it is actually simple and based on the production of such a U profile with a greater length, from which I then carefully cut off small 1 mm long pieces and close on one side. Thought and done, gluing the side strips (0,13 mm x 0,75 mm) to the base strip (0,25 mm x 0,5 mm) took place again in the proven manner by fixing between the rulers. Such a Steel ruler is also ideal for aligning the U profile, which happens to be 0,5 mm thick as on commission. Then the U profile was glued to the end strip (0,13 mm x 0,8 mm), which I deliberately left a little longer and fixed flat. However, since my steel angle for the vertical alignment of the U profile offers much more support, I then chose this arrangement, which made the gluing much easier. For final fixation while the Revell glue was drying, the deck ruler was moved to the stop, whereby the U profile was glued perfectly. For the separation of the end strip I've thought about this special fixation on a small steel block, after which the razor blade was used. To complete the bracket, only the end piece (1 mm) had to be separated from the U profile, for what I needed five rulers for fixation, which I arranged in such a way that I could now use the razor blade to score at least the upper edge of the two side strips on the 1 mm line, which only has a minimal overhang (0,25 mm), wherefore I had to take a close look myself with the headset magnifying glass over my glasses, assuming a steady hand. For the final separation of the mount I only had to be able to recognize these fine incisions, which is perhaps just visible here on this macro shot at an enlargement of 3553x2665, therefore here again somewhat larger with marking. When making a cut with a razor blade, the Jump away Protection tape is important in addition to a steady hand, which again has proven itself! The advantage of this variant is that I can now use the remaining U profile to make another nine mounts in the same way, wherewith the half would be done already. Edited March 18, 2023 by spaceman Quote Link to post Share on other sites
CaptKirk Posted March 18, 2023 Share Posted March 18, 2023 7 hours ago, spaceman said: Hello everybody, is there anybody in there? Should we nod if we can hear you? Or do you need some information first? 🤣 Very, very cunning plan to make such tiny parts so accurately. Had you ever considered being a vascular surgeon? Quote Link to post Share on other sites
crowe-t Posted March 18, 2023 Share Posted March 18, 2023 Manfred, I'm here. lol Excellent work on all these parts. Mike. Quote Link to post Share on other sites
spaceman Posted March 18, 2023 Author Share Posted March 18, 2023 2 hours ago, CaptKirk said: Should we nod if we can hear you? Or do you need some information first? 🤣 Very, very cunning plan to make such tiny parts so accurately. Had you ever considered being a vascular surgeon? Wait and see, maybe in my next life ... Quote Link to post Share on other sites
spaceman Posted March 18, 2023 Author Share Posted March 18, 2023 1 hour ago, crowe-t said: Manfred, I'm here. lol Excellent work on all these parts. Mike. Thanks Mike for looking in on me again after a longer time. Quote Link to post Share on other sites
crowe-t Posted March 18, 2023 Share Posted March 18, 2023 20 minutes ago, spaceman said: Thanks Mike for looking in on me again after a longer time. I may not post a lot but I'm always looking in. Quote Link to post Share on other sites
spaceman Posted March 19, 2023 Author Share Posted March 19, 2023 Thanks Mike for your staying interest in the background. I can understand you, what should you keep writing again and again too about such a long time ... Quote Link to post Share on other sites
crowe-t Posted March 19, 2023 Share Posted March 19, 2023 I read every one of your posts. As you know I've been following your build since day 1 and haven't missed anything. This is such an incredible build. It's amazing how you started building the paper kit and have taken it to this level of accuracy. Keep up the incredible work. Quote Link to post Share on other sites
spaceman Posted March 19, 2023 Author Share Posted March 19, 2023 Hi Mike, you are one of my most loyal companions all time and I know you've been in there from the start, which is why I looked back. That was 11 years before almost to the day (03/15/2012), what a long and memorable time to look back on fondly. And you were the second interested modeler after Bill (niart17) to reply that time. You also recognized early on the difficulties of the scale dilemma and raised concerns about the size of the SRB Blast chambers and TSMs that I only later realized after the Shuttle stack was test set up on the MLP. And that then led to the first larger emergency surgery of expanding the Blast chambers and using larger TSMs (1:144). In this respect, we were already fellow sufferers back then, because you also grappled with similar scale problems with your outstanding Revell 1/144 Space Shuttle stack as a tribute to Discovery's STS-133 mission and had to make compromises with the Revell MLP, which was simply too small. Source: EDU-Craft Diversions But there is a solution for everything, just don't give up. Quote Link to post Share on other sites
spaceman Posted March 21, 2023 Author Share Posted March 21, 2023 (edited) Hello everybody, let's go on with the production of the tiny Handrail brackets, which are held up the progress quite a bit, since you always have to let the glue dry before you can handle them any further. In the meantime I have arranged the steel block the other way around when cutting off the end strip, as this way I can better control the cut with the razor blade. The tricky separation of the U-profile can also be done in different ways, which is why I tried out a few things and switched to a larger sheet of steel as a base, which makes handling easier. And so it goes on step by step, re-clamping everything again and fixing it differently, over and over again, just don't let up ... Now it's also easier to score and cut off the tiny ones, and the U-profile is getting shorter and shorter ... The half is done, but a few brackets are also a little on the short side, and some still need to be adjusted in length, but which is doable. That's why I've prepared another U-profile, which I can now use to tackle the second half of the brackets, so hopefully I'll end up with 18 usable parts for the 8 Handrails. Edited March 21, 2023 by spaceman Quote Link to post Share on other sites
spaceman Posted March 24, 2023 Author Share Posted March 24, 2023 (edited) Hello everybody, and with it to the Final Cutdown. This was the chosen arrangement for the second half of the brackets for cutting off the U-profiles (1 mm) that I had previously scratched and marked with a pencil, here after careful cutting with a razor blade under sharp eagle eyes. And that's my valuable yield of 20 mounts (2 reserve) with approximately the same size. I had imagined the gluing of the mounts onto the handrails to be a little easier, but firstly it turns out differently, and secondly than you might think. As you can see in this image, the mounts are open at the front, so I have to glue the handrails rotated 90°, unlike I thought before. How good that I compared again. Source: forum.nasaspaceflight.com (STS-9, Ares67) The consequence of this, however, is that the gluing again requires a special fixation and I have to be hellishly careful that no holder flies away. That's why I have to glue each holder individually and with great sensitivity by using MEK, whether I want to or not. Although handling these tinies is indeed quite a fiddling, with the necessary calm and concentration one can do it! And so the handrail can then be glued to the Payload Canister. That's why I always say: Nothing is impossible! One just shouldn't set any limits! Edited March 24, 2023 by spaceman Quote Link to post Share on other sites
spaceman Posted March 25, 2023 Author Share Posted March 25, 2023 (edited) Hello everybody, today the Mounts were glued to the other three-legged handrail, wherewith the row at the bottom of the canister is complete. Then it was the turn of the two vertically arranged handrails above it, which have two mounts and were done more quickly. And so the image slowly completes, whereby I also still hinted the Personnel door through which one can arrive the Canister Payload Bay. Now only the mounts on the four upper railings are missing. Edited March 25, 2023 by spaceman Quote Link to post Share on other sites
spaceman Posted March 26, 2023 Author Share Posted March 26, 2023 Hello everybody, and these Mounts were glued today. At it the most difficult step was pushing the Handrail feet into the tiny mounts, which is why I "sharpened" them slightly. Then the gluing followed with MEK by carefully wetting the mounts with the finest red sable brush (10/0). This also finished the third Handrail pair, and could be placed on the template for fitting. It was finally the turn of the last couple, whereby the whole set is finally complete. And in this arrangement, all eight Handrails could soon be glued to the canister, as well as the Personnel door. http://www.raumfahrer.net/forum/yabbfiles/Attachments/up035091.gif So that nothing happens to them until then, I quickly brought them to safety in this little box. http://www.raumfahrer.net/forum/yabbfiles/Attachments/up050224.gif That's it then again. Quote Link to post Share on other sites
spaceman Posted April 3, 2023 Author Share Posted April 3, 2023 (edited) Hello everybody, now that the Handrails are safely stowed away until they are glued, I once again looked at the various doors, hatches and instrumentation panels on the canister. Although these are only small optical details, they give the canister its own face and should not be missing. From these details I then printed out true-to-scale copies from original photos and glued them on. First, there's this Personnel Door on the Forward Bulkhead of the canister, Source: forum.nasaspaceflight.com (STS-9, Ares67) which has to be tight and therefore quite robust, which is why I reinforced the thin paper a bit. The eight Handrails are then glued there too. The two Ladders in the first image were only hung in the Horizontal Transportation Mode in the Processing Facility. Since they would have gotten in the way when the canister was hoisted up in the RSS Payload Bay, they were removed before transportation the upright canister to the launch pad. After the canister was hoisted the workers of the Can Crew could enter onto the top of it via a fold-out Payload Canister Access Platform while wearing fall protections, as I've learned from James MacLaren and Richard Chamberlain. Source: James MacLaren, The Construction of Space Shuttle Launch Complex 39-B (Page 52) As one can see in this image and the next one, the canister is secured by "Umbilical cords" during the whole way from the Processing Facilities to the top of the RSS Payload Bay connected to the transporter. These are the two red hoses on the Port Side and this black cable bundle on the Starboard Side to ensure constant Clean room conditions inside the canister. Source: NASA (STS-93) And thus to the respective interfaces on the Side walls of the canister, on which various Instrumentation Panels are located, via which the canister is connected with the associated Modules inside the transporter that I already have described in my Reply posted January 18, 2022. Source: NASA Conference Publication 2342 Part 2 (M. E. Donahue) On the Starboard Side there are three I&CS Instrumentation Panels and a ECS Panel in front of them. Source: NASA (STS-135) The upper small panel is connected via five cables to the Instrumentation and Communication System (I&CS Module) at the rear end of the transporter, whereby the Climate and Clean room conditions inside the canister are constantly checked and monitored. I'm not quite sure whether I'll attach these cables (Ø 0,1 mm) later. http://www.raumfahrer.net/forum/smf/Smileys/yabb/undecided.gif In addition, I have to think about when I will attach which prepared fragile Assemblies (Door actuator, Screw jacks, etc.), since this will make handling the canister more and more complicated. Here the four panels are already glued. Further back on this side there is still this Access Hatch to the room below the payload bay to the Supply and Return Ducts, which via the red hoses are constantly connected with the transporter's Environmental Control System (ECS Module), which can be seen in the following photo. And so to the Port Side. At the forward end is a Personnel Door, which also leads to the room below the payload bay and the ECS duct attachments there, as well as the Pneumatic Interface Panel for the lower door seals. The front white Connection nozzle is connected to the ECS Supply Duct and the lower one to the ECS Return Duct. The red hoses are connected to it, which are connected to the ECS Module of the transporter and can be extended accordingly for the canister standing upright. Source: NASA (STS-135) The door and the Interface panel are already glued, but the connection nozzles are still missing and will follow soon. For the red hoses (Ø 2,2 mm) I have already found a suitable cable with a corresponding diameter. So it won't be boring. Edited April 3, 2023 by spaceman Quote Link to post Share on other sites
spaceman Posted April 4, 2023 Author Share Posted April 4, 2023 Hello everybody to early hour, today is a memorable day in the history of manned US Spaceflight, because on April 4th, 1983 Space shuttle Challenger took off with its crew on its maiden flight STS-6, Source: retrospaceimages.com (STS-6) L-R: Donald Peterson †, Paul Weitz †, Story Musgrave, Karol Bobko Source: wikipedia.org to which I have dedicated my long-term project, with which I'm going already into the 12th year. Source: nasa.org And as luck will it, on the day of the 40th Anniversary, in the 50th year after the last "Apollo" Mission NASA named the four astronauts for the "Artemis 2" Mission, scheduled to fly around the moon again late next year. Christina Koch, Victor Glover, Reid Wiseman, Jeremy Hansen Source: Josh Valcarcel/nasa/dpa If that's not a reason to be happy. Quote Link to post Share on other sites
crowe-t Posted April 4, 2023 Share Posted April 4, 2023 Manfred, Thanks for posting this information about Challenger's historic maiden flight and the "Artemis 2" Mission. Mike. Quote Link to post Share on other sites
spaceman Posted April 4, 2023 Author Share Posted April 4, 2023 Thanks Mike for your nice words, well, Real Space Modeling is my great passion and works like a drug, from which I just can't get away, especially since I keep discovering new and interesting details of this ingenious technique. But don't worry, a possible infection with this virus is completely harmless. Quote Link to post Share on other sites
spaceman Posted April 8, 2023 Author Share Posted April 8, 2023 (edited) Hello everybody, and thus to the ECS Supply and ECS Return Ducts of the canister, which are connected via the red hoses to the Environmental Control System (ECS Module) of the transporter. It's starting with the two white Connecting nozzles firmly connected to the canister with the Tube bows welded from five segments, whose dimensions I've determined from this photo. Source: NASA (STS-130) There one can see that the connecting nozzles sit on thin Base plates (0,13 mm) and that the tube bows are attached to nozzles with Clamping rings, which is why I also will build this assembly from four parts, which will later be connected with the red hoses. For scratch building the Tube bows (Ø 2,5 mm) I was able to go back to my tried and tested Balsa Bending Technique (BBT) by using a Hot air pistol. Next to the tube bows lie the Base plates (0,13 mm x 1,5 mm x 4,0 mm), on which the Connecting nozzles sit, as well as the Ring plates (0,15 mm x Ø 3,0 mm), which are glued between the nozzles and tube bows. The tube bows now need to be shortened to their final lengths, which are different as you can see in this image. Source: NASA (STS-104) But first I have to measure them again exactly, which will follow next. Edited April 8, 2023 by spaceman Quote Link to post Share on other sites
spaceman Posted April 11, 2023 Author Share Posted April 11, 2023 (edited) Hello everybody, and thus to the shortening of the Tube turns for the two ECS Ducts, whose dimensions are summarized here again. Source: NASA (STS-104) In view of the small dimensions of the arches, it quickly becomes clear that after cutting the bent round rods (Ø 2,5 mm) to the different lengths, not much of them will remain, what becomes clear after the cutting marks been attached. A firm fixation is required for cutting through the rod, which is why I clamped it in the Mini vise (Proxxon). Then the marking was carefully scored with the Mini saw (cmkkits.com) and the first cut (0,13 mm) was made, which was successful the first time. After the fringe was gently deburred, the second cut followed, after which only this unwieldy little worm remained. And while I was still smoothening this midget a bit, the bewitched mishap happened again that the damned thing slipped out of my fingers, and flew away into the space between the container and the sideboard. Luckily I found it among the plates stored there and after a breather I was able to continue. But below the tube turns there are still these strangely shaped Connecting nozzles (ECS Ducts), which I racked my brains about making for a long time. Source: NASA (STS-132) As one can see in the zoom, these ECS ducts have a narrow rectangular foot (1 mm x 3 mm) that rests on a base plate (0,13 mm x 1,5 mm x 4 mm), which widens in a funnel shape toward the tube turn to its diameter (2,5 mm). And in this change in shape from 3 mm (rectangle length) to 2,5 mm (diameter) is the difficulty for scratching the part. In order not to have to file this part out of a round rod (Ø 3 mm) from solid, I tried to crush a round rod (Ø 2,5 mm) at the end with a flat pliers onto the rectangular cross-section (1 mm x 3 mm), which did not result in a satisfactory shape in the end. But the flat crushing went much better with a round nose pliers, which was no less tricky because of that. But the result and the shape finally convinced me, here shortly before cutting off the tiny Duct nozzle. These are the four separate parts, of which the duct nozzle was now glued to the ring disc (0,15 mm x Ø 3 mm) and aligned. Then the tube turn was glued to the other side of the annular disc. Finally, the trio was glued to the base plate, finally completing this elaborate detail. And finally the test fitting of the red hose between the ECS Return Duct and the ECS Module of the transporter, and here the test fitting of the ECS Return Duct on the Payload Canister. And now the same procedure again for the ECS Supply Duct, wherefore however the tube turn on the connection duct has to be glued rotated by 90°. Edited April 11, 2023 by spaceman Quote Link to post Share on other sites
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