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Space Shuttle Launch Pad 39A with Challenger STS-6 (1:144)

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Thanks Tracy, :worship:


I know the decal sets by Steven Jochums, which are very impressive. up040577.gif

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Hello friends,


I've now chosen to glue the LO2 Feedline Brackets, for which I've now also used 1 mm Styrene, so that the strengths of the brackets on both sides are the same. cool.gif 


However, I've only glued the brackets to the Crossbeam, and not to the Feedline, because I still have to glue the rings next to the Feedline supports, as well as the front missing support behind the Intertank, for what I need enough freedom of action. 




The positioning and gluing of the tiny brackets was quite tricky, but then I've managed it quite well.  top.gif






And the Diagonal Cross Strut fits in between quite well too. speak_cool.gif




Then I've still glued the Resin-TPS-Claddings to the Vertical Struts, so they will not be lost. huh.gif




And now it can go on with the LH2 Cable Tray on the crossbeam. up040577.gif

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Hello everybody,


in order to be able to scratch-build the LH2 Cable Tray as completely as possible, which I'm intending, I first had to clarify its continuous course, which lasted long enough. rolleyes.gif And this course can be subdivided into two parts. top.gif


The first and much longer, but simpler part extends over the entire LH2 Tank, starting behind the Intertank, and then flows into the right Vertical Strut at its top end (see yellow circle). For the moment, however, I will defer this part until later, because it has to go along with the laying of the Ice Frost Ramps of the GH2/GO2 Press. Lines, what will follow later.  


Source: forum.nasaspaceflight.com (DDG40)


In this strut, the cables then run upwards and enter the gray "Distribution box" from behind, 


Source: forum.nasaspaceflight.com (DaveS)


and from there the cable tray runs on the front side of the Crossbeam to the other side, which I will show in more detail. cool.gif


Source: Scott Phillips


And now follows the difficult and time-consuming part of every scratch exercise, in which I always have to determine the required dimensions of the individual parts by using suitable reference photos/drawings. rolleyes.gif


One is spoiled for choice, depending on which reference measure (yellow) one refers, either to parts of the original photos, or to those of the Airfix Kit, which then sometimes can lead to a compromise between the two possibilities, so to speak on something between.  hmmm.gif   


In the following photo, the transition from the "Distribution box" to the following Cable Tray is unfortunately covered, which is why I had to determine it by appropriate cutting lines to be able to estimate its dimensions.  




The dimensions of the "Distribution box" can indeed be determined well from the next image, but here the transition area to the cable tray is covered, which is why no clear reference dimension can be found. That's why in anticipation of the next photos I used the height of the Cable Tray (2,7 mm) as reference measurement.




This is the already oftener shown photo by DaveS,


Source: forum.nasaspaceflight.com (DaveS)


on which one can see in a rotated and greatly enlarged representation of the transition of the LH2 Cable Tray from the vertical strut into the "Distribution box" very clearly, whereby the oblique perspective allows no accurate measurement of the parts. hmmm.gif




But there is this photo by George Gassaway


Source: georgesrockets.com (George Gassaway)


which, in rotated and enlarged view, allows some important estimates due to the almost direct view, as well as the height of the Cable Tray (2,7 mm), previously chosen as a reference measurement, which in turn was determined from the diameter of the Thrust Strut of the Airfix Kit (Ø 3,2mm). speak_cool.gif




And so the LH2 Cable Tray arrives on the other side of the Crossbeam, whereby here one also can see well the TPS cladding of the GH2 Press. Line. And from there it is only a short distance to the LH2 Umbilical Plate, into which both the Cable Tray and the Press. Line are inserted from the bottom, wherewith we finally arrived at our destination. top.gif


zlYsD3.jpg  io79ud.jpg
Source: georgesrockets.com (George Gassaway)                                   Source: capcomespace.net


And so now for the practical implementation, wherefor which I have used this drawing from the ET Bible.


Source: System Definition Handbook SLWT, Vol. II (Lockheed Martin)


Into this drawing, I have drawn as a reference measurement the distance between the two support points of the Airfix orbiter (32 mm) and then reduced the drawing to 1:144 and also still mirrored. huh.gif

And with this I have now tried to draw a true to scale template for the Cable Tray with the appendage of the "Distribution box" and print out, which I also managed to some extent.   




But what looked just so nice and catchy on the photos yet, shrinks on a scale of 1:144 after the expression again together in such a way, so I had to look twice when cutting out the Cable Tray.  cant-believe-my-eyes-smiley-emoticon.gif




And that's what the part looks like on the Airfix Crossbeam, top2.gif




which I now only need to transfer to 0,5 mm Styrene sheet and carefully to cut it out. smiley215.gif


On the right side of the Cable Tray one has to add this rounding and, if possible, also the 90° bend to the front, which one can see well in the zoom on this photo of the ET-121.


Source: NASA


And for completion, all that is still missing is the TPS cladding of the GH2 Press. Line, which will be made later.  up040577.gif

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Thanks my friend for your nice compliment, up046068.gif encouraging me to continue and not give up. up040577.gif

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Hello everybody,


as one can see in this photo, the TPS Cladding of the Vertical Strut is reaching still a bit more upwards, has a few steps there and looks thus a little bit different than the Newware-Resin-Cladding. huh.gif 


Source: forum.nasaspaceflight.com (DaveS)


In order to enable the connection to the Distribution box of the LH2 Cable Tray based on the original, I have tried to recreate these details and have glued tiny particles of the narrowest and thinnest Evergreen strips around the strut,






what was again a delicate fidding, smiley_worship.gif whereby the transitions still need to be slightly sanded.




Then I've fixed the paper template of the LH2 Cable Tray with the Distribution box on the Crossbeam again to see whether or how this matches with the clearances, and whether there is still enough space for this box, smiley215.gif




which could be about right, as one can see here. speak_cool.gif




Then I've transferred this template onto a 0,5 mm Styrene sheet and cut it out piecewise, for which I used my finest Mini-saw (0,1 mm) for the long cuts and for the short cuts my Chisel cutter






And after that long cut, the part has been finally exposed, 






and was then finely smoothened at the edges.




The following test fitting of the Cable Tray at the Crossbeam looked quite well,   






so that I could turn to the small Distribution box for which I've used an Evergreen square profile 1,5 mm x 2 mm,




which, however, was difficult to handle. rolleyes.gif








As the test fitting of the Cable tray with the glued box shows, the seat is quite neat, so that only the sloping bottom side would be something to straighten. 






Then only the cable connection would have to be attached, after which it could then continue on the other side.  up040577.gif

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Hello everybody,


in the meantime, I've attached this Cable connection between the Vertical strut and the Distribution box, for which I've glued two tiny pieces of Evergreen Strip which are barely noticeable. cant-believe-my-eyes-smiley-emoticon.gif 




And now to the other end of this Cable Tray in the red circle, which after the arc at the end firstly goes down and then immediately runs rearward in a short 90° arc underneath the Crossbeam


Source: NASA


This course can be followed in the following photos. 


Source: NASA


Source: georgesrockets.com (George Gassaway)


Source: capcomespace.net


In this drawing, the course of the two Cable trays is simplified depicted, but what is helpful for scratch-building. top.gif


Source: System Definition Handbook SLWT, Vol. I (Lockheed Martin)


Behind the crossbeam follows at the end of the cable tray the angled transition of the parts with TPS Cladding (2, 3, 4, 5) up to the Umbilical Plate under the orbiter, which seems to be difficult to scratch due to the minimal dimensions of the parts, smiley215.gif especially since the clear height between the Cable Tray and the Umbilical Plate is only 3 mm, from what the height of the CT transition to 4 mm results, which should become quite tricky. analintruder.gif


Source: georgesrockets.com (George Gassaway)




Afterwards I've tried the arc of the Cable Tray on the front of the Crossbeam with the help of my Balsa & Bending Technique. huh.gif 










During mounting one has to make sure that the Cable Tray is not directly in contact underneath the Crossbeam but sits on a small spacer (0,4 mm) which is already glued here.




As the test mounting shows, however, from the arc would leave almost nothing left, which would probably complicate a flush connection. rolleyes.gif




Therefore, it will probably be better if the cable tray is first glued to the front with a bit of supernatant, after which a matching strip is glued  in the interspace which then is rounded.  up045518.gif


And this construction I've tested provisionally with tape, 




and was surprised that the clear height between the Cable tray (0,6 mm x 1 mm) and the Umbilical plate is actually 3 mm and thus is perfectly in accordance with my previous estimates of the measurements.  speak_cool.gif




And this is a first attempt to make the TPS arc (part 2) from a rectangular profile 1,5 mm x 3,2 mm,




whereby I am looking forward to the result.  up040577.gif

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Wow and ... WOW ... your ability to observe the detail and then ... THEN to be able to replicate it in such a tiny scale is ... just ... plain ... remarkable!


And it's not just the general detail but the complicated routing and complex details of, for instance, this cable tray.


I don't even want to think of how you're going to replicate the RSS ... my goodness!  :worship:   :thumbsup:


You're doing a superb job Manfred! ... Carry on!


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Thanks Pete for your nice words and the appreciation of my work, :worship: which is really no walk in the park when scratching such tiny details on this scale, but I still enjoy it. :coolio:


BTW, I also don't want to think about the RSS with its monster structure yet, therefore all in good time, and no worries!!!! top.gif


In this sense, the show must go on and please keep your fingers crossed! JC_doubleup.gif

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Hello everybody,


but first I've continued with the LH2 Cable Tray and the associated tiny parts of the transition, which are all in the millimeter range and thus extremely tricky to handle, what only is feasible under the Headset magnifying glass. cant-believe-my-eyes-smiley-emoticon.gif


In the process, I carefully approached from all sides using my file set and my finest mini-saw (0,1 mm), whereby one must keep an eye on the required dimensions, which is for this bow 1,5 mm x 1,5 mm, which is why one has to measure again and again. huh.gif








And since I prefer to work with a little bit of excess, a post-processing is still necessary, which becomes particularly tricky once the part has been sawn off. As a result, an undersize can quickly arise, which is not so good. smiley208.gif


So, choosing the Rectangle profile of 1,5 mm x 3,2 mm was not exactly brilliant and has unnecessarily complicated the whole procedure. smiley_worship.gif


That's why I used a Square profile 1,5 mm x 1,5 mm in the second attempt, which was much "easier" to handle, since the outer dimensions are already fit, and what I could have done better immediately.  up040472.gif 


At first I filed the rounding and then sawed off the length of 1,5 mm.


However, care should be taken during the following processing of this mini-piece,




whereby I held it for filing the inner rounding with my Precision file (Ø 1 mm) in a Cross tweezer and at the same time supported it from below with the finger.  speak_cool.gif




And since the test fitting of the bow on the Cable Tray looked good,




I then glued the bow carefully, 




and something aligned yet, which resulted in a good fit of the bow. top.gif




Then I've cut the Middle plate (part 3) out of a Rectangular profile 1,0 mm x 1,5 mm x 2 mm,




and glued it onto the bow.




And after the successful fitting I was able to catch my breath,  popcorn.gif




because this transition fits quite well and there is still enough space for the oblique transition to the Umbilical plate (parts 4/5). top2.gif




And with this intermediate result I can be quite happy. up040577.gif

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I continue reading this thread and shaking my head in wonderment for the things you do and how you accomplish them.  Wunderbar!

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Thanks Bruce for your nice words, :worship:


yeah, sometimes I am astonished myself, what crazy things I'm doing there for fun at the joy ... up040577.gif

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Hello friends,


here's an image with the three ports under the LH2 Umbilical Plate that I have to set my sights on. cool.gif




The diameter of the GH2/GO2 Pressurization Lines is 2'', accordingly Ø 0,35 mm at 1:144, and the diameter of the LH2 Recirculation Line is 4'' (Ø 0,7 mm). By comparison, the diameter of the LH2/LO2 Feedlines is 17" (Ø 3 mm).


At the transition of the GH2 Press. Line is still missing the oblique transition (Parts 4/5) to the Umbilical Plate, which one can see in this photo of the ET-118 (STS-115),


Source: NASA


which should follow now. top.gif 


This is a small disc Ø 2 mm x 0,3 mm for Part 5, and the slant for Part 4 is cut of an Evergreen Strip (1 mm x 1,5 mm).




First of all, I wanted to reinforce and file the slant by side-glued Strips 0,25 mm x 0,7 mm, as the true part widened in a funnel shape towards the top, as one can see on this image, but which would be overkill because of the "size" (see above), smiley_worship.gif which is why I decided not to.


Source: NASA


But the test fitting looks quite good, I think.




When glueing such tiny parts, it depends on a precise fit, which is why you have to position them exactly and unshakeably before, what I have done here this way. 




So that the parts do not grow beyond the clear height of the transition (3 mm) due to the bonding, which would happen with normal Revell adhesive, huh.gif I've glued them with MEK , which is why I've used a Teflon film, so that nothing sticks to the cutting mat.




And this is the result, 




and this slant could now be glued to the Cable Tray bow, which was again a tricky business. rolleyes.gif






Well, and during the tricky test fitting of this now complete LH2 Cable Tray, the mishap happened to me as the part slipped out of the tweezers and fell to the floor, whereby unfortunately, the painstaking glued slant is broken off ... erschrocken3.gif ... up043952.gif


So that this does not happen again after the repair, I've glued the plate with MEK onto the underside of the Umbilical Plate and centered it in place with a needle. 




And in this position, I then laid on the 'patched' Cable Tray carefully and glued onto the Crossbeam and under the Umbilical Plate.








And so it looks like on the front of the Crossbeam, where I still have to scratch the the connection with the horizontal Cable Tray




for which I glue first suitable strips in the gap, what from subsequently the lower bow will be sanded.  up040577.gif

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Hello everybody,


sorry, but these images to the scratching the Cable Tray Bow have fallen by the wayside somewhere, so I want to add them, which is done quickly. cool.gif


With these two strips I've filled the gap,




then the supernatant was cut off with the Cutter chisel




and thereafter the rounding of the bow was gently sanded.




And that was it already! top.gif






And now to the already announced GH2 Press. Line incl. its TPS cladding, which runs under the leading edge of the Crossbeam, what one can see on this photo of the ET-121 (STS-114) especially well in the zoom, top.gif


Source: NASA


and also here on this photo.


Source: forum.nasaspaceflight.com (DDG40)


On the next photo (left) one can see the end of the TPS cladding with the exit of the Press. Line, whose bottom is rounded. Furthermore, one can see that the Cable Tray initially opens into a flat wider distributor, from whose side still a separate Cable Tray branches off into the Vertical strut in which the cables are routed to the ET/SRB Attachment, as one could already see on the LO2 Side on the opened Vertical strut. (s. Posted June 14). top.gif 


On the right image one can see the end of this flat distributor as well as the separate branch in the vertical strut from a different perspective. The only pity is that the slant transition of the Cable Tray to the Umbilical Plate is covered by this cuff. smiley_worship.gif


Source: georgesrockets.com (George Gassaway)


Source: NASA


For those who love detailing, on this matching photo of Scott Phillips one can see this branch-transition with cables laid open. speak_cool.gif


Source: Scott Phillips


On the following drawing, the arrangement can be seen at this point in cross section. And as one can furthermore see the previously installed Cable Tray is still attached with two holders to the outer LH2 Feedline Bracket,

Source: System Definition Handbook SLWT, Vol. II (Lockheed Martin)


what is also nice to see in this photo and is still on my To-do list ...up035091.gif


Source: NASA


And now to the TPS cladding of the GH2 Press. Line, for which I've glued an Evergreen Strip (0,25 mm x 1,5 mm) with a Semi-circular profile (0,65 mm x 1,5 mm), Which I've drilled off on both ends for the 2'' Press. Line with Ø 0,4 mm, for which I use a German silver round profile (Ø 0,4 mm).




Here, the TPS cladding is already glued under the Crossbeam and the Press. Line was inserted from the LO2 Side by way of trial.




And here the previous ET/Orbiter attachment sits on his place and makes a good impression.cool.gif






Next, I will try to scratch this flat and the front mounts, and then as the crowning end of this side the end of the GH2 Press. Line will be installed. up040577.gif

Edited by spaceman

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Hello everybody,


let's go on with this crazy Cable Tray stuff, most of the details of this LH2 Umbilical with the corresponding Cable Tray are done, cool.gif but at looking closely, I've still noticed a few inconsistencies. hmmm.gif


But first to those missing details, which are relatively clear, like this lateral branch from the Cable Tray Distributor as well as the following arcuate transition into the Vertical Strut. This lateral branch is relatively easy and quick to lay, as it has the same dimensions (0,6 mm x 1 mm) as the Cable tray running in front of the Crossbeam. top.gif


Source: georgesrockets.com (George Gassaway)                                      Quelle: NASA


But then comes with the narrow bow (red circles) into the TPS cladding of the vertical strut the trickier part. Although this is similar to the bow of the cable channel at the transition to the Umbilical plate and was filed again from the solid, for which I've used a Rectangular profile (1 mm x 1,5 mm), but this bow had to be significantly narrower, so the handling was even more difficult this time. smiley_worship.gif




To fit into the narrow gap in front of the vertical strut, this bow was allowed to be only 1,5 mm wide, as can be seen here. And so the fumbling when glueing this stub was pretty stressful again ... eek.gif




After several test fittings and patiently step-by-step sanding of the part, the mounting did succeed.  up045518.gif


Afterwards I've extended the TPS cladding (Newware) like on the other side at the upper end and finally glued this small upper mount, 






whereupon I had to take a breather first.  popcorn.gif


And once in the exercise, it went on with the two tiny Cable Tray mounts behind the Crossbeam, which can be seen here. 


Source: NASA


For the parts sitting on the cable channel (0,5 mm x 0,5 mm), which reach to the outer LH2 Feedline Bracket, I had to stick together two Strips 0,25 mm x 0,5 mm  because I currently have no strip 0,5 mm x 0,5 mm in stock. rolleyes.gif




Since these stubs had some overhang, I had to remove it subsequently, which turned out to be an extremely difficult task, as there is hardly enough room left for handling at this bizarre structure and the breakage risk was very high on top of that. omgsign.gif




So only gentle and careful sanding remained as the only solution left huh.gif which then worked reasonably well. Then I glued the lateral holders (0,25 mm x 0,5 mm), the supernatant of which was separated from below with a narrow razor blade,






whereupon everything was still carefully sanded with a narrow self-made grinding stick (500 grit). speak_cool.gif






And then it went on with the cover of the Cable Tray Distributor, which was shown in the first picture (left, below the circled branch). For this purpose, the cable channel received lateral strips of an Evergreen strip (0,25 mm x 1 mm) and a cover made of 0,1 mm Styrene, the shape of which I had to modify a bit due to the space available, as one can see here. hmmm.gif










Finally, the missing claddings were glued at both Vertical Struts






whereby next, the mounting of the transition of the GH2 Press. Line will follow. up040577.gif

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Hello everybody,


okay, then I want to dabble as a pipe bender with the GH2 Press. Line -  The proof is in the pudding. top.gif


Therefore, I have put together the matching pictures once more, on which one can see the course of the line well. 

On the following photo (left) it looked for me at first as if the line behind the pipe joint slightly obliquely go up, which is not true, because the kink goes namely down, as shown in the photo (right) able to see.  up045518.gif


Source: georgesrockets.com (George Gassaway)                                          Source: NASA


As already mentioned, the pipe should have a diameter of 0,4 mm (2'')


For the first test bending I have used Copper wire (Ø 0,4 mm) because it is bendable nicely and certainly some corrections will be needed until the shape of the line is adjusted, I think. smiley215.gif  


And after a few fittings and slight corrections in narrowest space, the result looked like that, which is nothing to sneeze at, as I think. speak_cool.gif




The two drilled holes in the Cable Tray under the Crossbeam, as well as in the Umbilical Plate proved to be advantageous for the mounting of the line, who gave a certain amount of support during threading and correction. top.gif






Hopefully the Nickel silver wire will let bend a bit more exactly. But for now, I'm already very happy with the result so far. up040577.gif

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Looking at your steady progress, if you could see me Manfred, I'm smiling from ear to ear in amazement ... in appreciation of your added detail.   :woot.gif:


I do hope you're really enjoying this build ... enjoying all this research and making this enormous effort in replicating the smallest detail ... my, my, my ...... I know, I enjoy seeing every post of yours!  :thumbsup:



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Thanks Pete for looking in on me again, :worship: your response is always balm for my soul, because you honestly mean what you say. top.gif You are holding up the ARC flag!!!  smiley250.gif


As you know, all this research is necessary to get behind these details and are for me half the rent, as the Germans say. up045518.gif


BTW, do you think there are enough details scratched when you look at the first two photos, or would you miss something else? :hmmm:

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Okay my friends, here let's go on. :coolio:


So far so good, but now there are on the GH2 Press. Line even these four Fittings, which in my estimation should have a diameter about of 1 mm and a width of 0,5 mm. hmmm.gif


Source: NASA


And who knows me a little bit, probably suspects that I will try these things at least once. top.gif At that at first I thought of my Lead wire Ø 0,4 mm, which I already used for similar things on the SSWS Pipes. smiley215.gif


For this I wrapped the lead wire around the Copper wire (Ø 0,4 mm) and then separated this spiral with the Cutter chisel.




Then I rounded the rings around the copper wire with the tweezers to close the tiny gaps,




which then look like this. cool.gif




The threading of these rings onto the bent line was then a tricky puzzle, but let still carry out. rolleyes.gif The insertion in contrast was rather difficult because the space for the tweezers for handling is very tight and the rings have partially bent up.  smiley_worship.gif










But I was not thrilled by this result, however. nono.gif

Then the thought of thin insulating tubing came to me, idea1_2.gif which I have already used successfully for such tiny rings. 




To make as nearly as possible rings with the same width, I put the hose between steel rulers and then separated pieces of 0,5 mm.




These rings look a bit more like the real fittings, because their sides are straight, and they were also easier to thread up, 




and the result when installed looks in my view also much better than with the Lead wire rings.  speak_cool.gif Maybe the rings could be still a little bit narrower. ??? 






The only question is again whether the effort is worthwhile, because one can barely see this Press. line on the upright Shuttle stack later anyway, how some other details also not, even though if the master builder would be more satisfied. up040577.gif

Edited by spaceman

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On 9/6/2019 at 3:54 PM, spaceman said:

BTW, do you think there are enough details scratched when you look at the first two photos, or would you miss something else? :hmmm:


You know, when I read this, I thought to myself, I should mention the "P" clip insulators, but no I won't, because that's just not very amusing ...


So what do you choose to build? Those Insulators ... and ... they ... look ... GREAT! The 2nd attempt is much better!  :thumbsup:


Well done Manfred!


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Thanks Pete,  :worship:


yeah, I do not know the exact name of these parts, but we mean the same things. smiley250.gif


But you could have told me that calmly, for tips from an authoritative source I'm always grateful.  up040577.gif

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Hello everybody,


today I have made a few more experiments to make these Fitting rings, wherefore I've fished out again my Punch & Die Set (USM). cool.gif


I first used Styrene (0,5 mm), from which I punched a small disk with Ø 1 mm,




which then was drilled out with Ø 0,4 mm






and then was threaded onto the Nickel silver wire (Ø 0,4 mm)




The same procedure I did for comparison with Styrene 0,4 mm, whereto I used a normal Fileback fastener. top.gif




This somewhat narrower disc can be seen to the left of the 0,5 mm disc, and above that the rings made of Insulating hose.




Due to the uniform thickness, the punched rings would certainly look more even, whereas the rings made of Insulating hose are easier to manufacture and better fit the contours of the Cable Tray and the Feedline. As a result, I'll probably stay with the insulating hose variant. up040577.gif

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