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

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Hello everybody,


and today the new GH2 Press. Line made of Nickel silver wire (Ø 0,4 mm), which is bent even more precisely, whereby it can easier cling to the Cable Tray and around the LH2 Feedline. speak_cool.gif


Bending the wire was a bit more difficult, as the Nickel silver wire is less ductile than the Copper wire, but after a few tries it went smoothly. cool.gif






And also with the Fittings from insulating hose the line fits well. up045518.gif


When inserting, I always put the long end first in the opening in the Umbilical plate,  




and then the front end into the in die TPS cladding of the Press. Line. top.gif




This allows me to paint the line separately and then finally insert it.




After that the LH2Umbilical is done, I can go on with the LO2Umbilical on the other side, where again the Cable Tray with the Supports has its turn.  up040577.gif

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Hello everybody,


so then let's go to the LO2 Umbilical, which can be seen from behind especially in the zoom in all its beauty. up045518.gif 


Source: NASA


Observing from the front, it is noticeable that at the LO2 Feedline there is still this special Support, which is rather thin and sits directly below the LH2 Cable Tray on the Crossbeam. huh.gif Or maybe it's a part of the TPS Cladding of the Umbilical.  hmmm.gif  


Source: forum.nasaspaceflight.com (DDG40)


For the further separate construction of the ET/Orbiter Attachment, I have considered that it would be better to cut off the LO2 Feedline at this point and to glue the back bow with the LO2 Umbilical plate between the two Support Brackets and then to glue the thin support onto the front end of the bow. Then the other Support/TPS parts and the LO2 Cable Tray as well as the end of GO2 Press. Line will be installed.


The front part of the Feedline is too short anyway and has to be extended up to the Fairing on the Intertank


And only after the Flour coating process and painting of the ET all lines including the Ice Frost/PAL Ramps as well as the complete ET/Orbiter Attachment will be installed on the tank. top.gif




Before cutting through the Feedline I first had to find out the geometry and the dimensions of the Support-Plate, which was not that easy, because the parts are only temporarily attached.  smiley215.gif 




With the measured distance between Feedline and Cable Tray of approx. 2 mm I drew this little sketch, 




which I then transfered to Styrene (0,5 mm)




then it was punched out with the Chisel-cutter,  




which then was sanded. up045518.gif




And this is how the test fitting looks on a Feedline dummy (Ø 3 mm). cool.gif






That's it then again, next follows the separation of the Feedline and the test fitting of the bow.  up040577.gif

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Hello friends,


the marking of the separation point on the LO2 Feedline was more difficult than expected due to the limited space conditions, smiley215.gif but then I still succeeded. And then I bravely took the saw, and the job was done. cool.gif


These are the first images after the separation of the Feedline with the realization that the short bow was much harder to handle for testing, which is why I had to think of a new solution.  idea1_2.gif


And so I came back to my Transparency stencil, which was made for it and only had to be slightly shortened.  speak_cool.gif This allowed the bow with the stump above the Umbilical plate to be inserted into the large opening of the template and kept relatively stable.




And by clamping the template in my Mini vise, the bow was easy to see from all sides.  spiegel-smilies-0002.gif




I was pleasantly surprised at how well the front of the bow did fit under the Cable Tray,  top.gif




which was visible by placing the paper template. 




But after putting on the 0,5 mm Styrene support plate, the disillusionment came immediately,  analintruder.gif because I had not thougt of it that the Cable Tray is also 0,5 mm thick, and the support plate with this then would be flush, but this is not correct because it must sit a little lower.up040472.gif 




Consequently, either a thinner support plate ago, or the plate had to be ground down to about 0,3 mm, which I then have preferred. huh.gif


But more on that later. up040577.gif

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Hello everybody,


no sooner said than done! cool.gif So I've sanded the Support plate between two nail files to a thickness of about 0,3 mm, and I have to say that I liked it better than before. top.gif







Now, the bow had to be glued as exactly as possible between the Support Brackets, but unfortunately I had to remove the stencil, which had previously fixed the position of the bow. huh.gif






The crunchpoint here, however, is that the bow must be aligned with the Feedline,




and the Umbilical Plate should lie flush against the opening of the Orbiter Door.smiley215.gif




To accomplish this, I drilled the end of the Feedline in the middle and inserted a piece of Nickel silver wire as Centering aid






In this way I succeeded, first to glue the Support plate at the Crossbeam and then the Feedline-bow with the Support brackets, which will make the further work on the parts of the Cable Tray-TPS cladding much easier, since nothing can slip anymore. up045518.gif




Then I've bent an Evergreen Strip (0,4 mm x 0,5 mm) under hot air around a rod (Ø 3 mm) and glued one ring of it in front of the Support plate. 




Then I've scratched the so called Pivoting Support missing at Airfix and glued it just behind the Intertank.  




But this is only one half of the Feedline Support, as one can see in this image, as there is still a clamping ring over it, 


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


which should be much narrower than at Airfix existing ring, as the comparison with the original photo shows, so I would have to modify these rings also a bit. rolleyes.gif 


Source: forum.nasaspaceflight.com (Jester)


Then there are also missing the wider Rings in front of the supports, which I'll scratch too.


So all in all a lot of odds and ends, which is still waiting for me.  up040577.gif

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Hello everybody,


and now to the LO2 Cable Tray along with the TPS Segments at the transition to the LO2 Umbilical Plate. cool.gif


As always, before the Scratch-building of assemblies and parts there is nothing like a thorough inventory and accurate detailed analysis. smiley203.gif ... up050987.gif ... idea1_2.gif


The beginning is again this photo for a better orientation, which helped me because of the direct side view already in the sizing of the Distribution box, on which I have marked the first three parts of this LO2 Umbilical assembly


Directly behind the distribution box is with the Part 1 a trapezoidal support part whose dimensions (length L, and upper and lower width) I've determined by reference to the diameter of the LO2 Feedline (Ø 3 mm). up045518.gif


Source: georgesrockets.com (George Gassaway)


On this rotated photo, one can see this here gray part a bit closer, whereby the linked original zoom is unfortunately rotated. rolleyes.gif


Source: forum.nasaspaceflight.com (DaveS)


Therefore, here is still a section in the original resolution, on which one can see that this part is directly connected with the Distribution box and with the LH2 Cable Tray.  up039822.gif 


And directly behind the oblique branch (Part 3) runs from the Cable Tray, which is connected with the Part 2 and passes over the Parts 4/5 to the Umbilical plate.  




Thus, only the width of the part  is missing, which I have determined from this photo, which allows me to scratch the Part 1.  up045518.gif




In this picture one can see the cables coming out of the vertical strut, of which one part, as just described, runs up to the LO2 Umbilical plate and the remainder to the LH2 Umbilical plate


In this rear view, the Parts 3-5 are admittedly covered by cuffs, but one can nicely see the entrance of the LH2 Cable Tray into the Vertical Strut. up045518.gif




And in this order, I will now try to scratch these five parts step by step.  up040577.gif

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Dude! I haven't stopped by and commented in a while but my goodness I'm still blown away with your precision and eye for detail. AMAZING! And also, how do you get so much awesome resource photos? Some of them are shots I've never been able to find. My right mouse save button is wearing out following this thread. :cheers:


Keep up the amazing work!

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Thanks Bill for your nice compliments. :worship:


Well, there is nothing like good reference photos, if possible in high resolution, and I have lots of them by now. top2.gif


These details always look huge on them, but when I see in 1:144 how tiny they are, then I have greatest respect when it comes to scratching ... eek.gif


The only downside is that one barely still can see them with the naked eye on the model, cant-believe-my-eyes-smiley-emoticon.gif but that's not worth mentioning. up040577.gif


Stay tuned my friend. smiley177.gif

Edited by spaceman
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Your search and attention to detail is truly amazing.


Add the precision of each component and the patience to execute it.


Thank you for sharing your work and in the end give your work more greatness.



we are in contact





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Hello everybody,


and now to the Part 1, which is small, but looks relatively simple, although in this image it is half hidden by the Distribution box. huh.gif


Source: georgesrockets.com (George Gassaway)


After I had punched it with the Chisel cutter out of an ABS Plate (1 mm) and smoothed the edges, it was glued at this point, directly in the corner between the Distribution box and the Cable Tray,




as one can see in these two images. 






Then it went on with the Part 2, whose shape one can only partially see in the photos, which has made the determination of the dimensions more difficult. rolleyes.gif Therefore, here again for a better distinction the color-coded Parts (1-6) with their partially hidden contours. top.gif


Source: forum.nasaspaceflight.com (DaveS)


In the next photo, it looks like Part 2 is directly adjacent to the green end part of the Crossbeam (Ball interface fitting), what I first assumed, but which is not the case.  nono.gif On the other side, it is directly adjacent to the LO2 Feedline Bracket, what one can clearly see in the zoom. cool.gif 


Source: NASA


And from this image I have determined some dimensions of the parts, whereby in my experience for the determination of Heights one should also use a Reference height, and for Widths accordingly a Reference width too.  up045518.gif




Since this is still not enough to be able to scratch the parts, I've analyzed this already several times shown photo (rotated) for the remaining dimensions, which is very well suited because of its high zoom resolution. speak_cool.gif


Source: forum.nasaspaceflight.com (DaveS)


However, this image is very confusing due to the many dimensions, rolleyes.gif which is why Part 2 can be seen here again separately. 


Strictly speaking, the bottom of the part is not flat, but has down this triangular extension, but which I have not marked here and will suppress, since with about 0,4 mm it should be almost "invisible" and can be safely neglected ... hmmm.gif




With these dimensions, I've then tried to scratch the part, whereby I first wanted to place it in an Evergreen strip (1 mm x 2 mm)




but which seemed a bit too puny to me. smiley_worship.gif Therefore, I will start another trial with an ABS Plate (1 mm) too.




Previously I had drilled the opening for the GO2 Press. Line (Ø 0,4 mm) into the Umbilical Plate and threaded the Nickel Silver Rod on a trial basis.  




That should be enough for today.  up040577.gif

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Hello friends,


today first again the experiment with Part 2 on a ABS Plate (1 mm), in which the slope should come out better than with the narrow Evergreen profile (1 mm x 2 mm). cool.gif This time I have also taken into account this triangular extension on the bottom, which could be eliminated if necessary. 




The punching with the Chisel cutter went relatively well, so that the contour had to be filed then only slightly, 




what was again the same tricky procedure as the first time, because the part was barely could kept between the fingernails, but only in the tweezers tip, and even then slipped again and again.  smiley_worship.gif




In this image, one can see both parts in comparison, whereby the new part looks much more precise, whereby the lower extension is about 0,5 mm. top.gif 




And this is roughly the mounting position right next to the outer LO2 Feedline Bracket,  




which of course I have tested by laying up the part, and what looks pretty good for now.  speak_cool.gif






Only at the point marked in red, I have to take away a little bit of the Crossbeam (Ball Interface Fitting), so that the narrow strip can advance a bit further, so that the tip of the part will be lined up precisely with the Feedline Bracket. up045518.gif




Next, with Part 3, the probably most complicated assembly group of the LO2 Umbilical comes along, which presumably will be built from several components. smiley215.gif




With that, in particular, the connection point of the channel running diagonally forward to the LH2Cable Tray must be determined even more precisely, which unfortunately is in hiding and so far could only be hinted at.  hmmm.gif


So all in all, a rather tricky matter in a confined space, which is why every handle wants to be well considered again. up040577.gif

Edited by spaceman
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Hello everybody,


let's continue with the adjustment of Part 2, for which here beside the Crossbeam (Ball Interface Fitting) the announced narrow recess was cut out with the Mini saw blade. cool.gif




And as one can see, it's only a small cut, but leads to a clear improvement! smiley250.gif




Speaking of Original arrangement, I'm not sure anymore when I take a closer look at my black and white reference photo of the tank ET-8, up047089.gif which as is well known was to be the firstly flown Lightweight Tank (LWT), that was used since STS-6. Only at STS-7 was used a Standard Weight Tank (SWT) once again, for whatever reason. huh.gif 


Unfortunately, the resolution of the photo is not exhilarating even in the zoom, and the area of interest to me is in the dark and is unfortunately also obscured by the Vertical Strut.  up039493.gif 


Source: forum.nasaspaceflight.com (Jester)


But if you bend your eyes and look more closely, cant-believe-my-eyes-smiley-emoticon.gif you will recognize, I believe, that especially the obliquely upwards running part of the Cable tray behind the support (Part 2) seems to be much narrower than on the previously considered images, which however, from later missions, where starting from STS-91 the Super Lightweight Tank (SLWT) was used, which had been modified again. up045518.gif




To the following photo I will still inquire DaveS, from which mission it originates. rolleyes.gif


Source: forum.nasaspaceflight.com (DaveS)


And this photo shows the ET-122 at the last mission of the Endeavor (STS-134)


Source: NASA


Let's see if I can get some more information from DaveS, because sometimes he still has cool photos up in his sleeve, which have already solved some riddles.  up040577.gif

Edited by spaceman
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Hello everybody,


and DaveS' answer was not long in coming. cool.gif He can not remember the mission from which his great photo came from, huh.gif but as far as he knows, the Cable trays did not change during the Shuttle program and remained same from ET-1 (STS-1) to ET-138 (STS-135), which I did not want to believe at first. up047089.gif


Because similar to here on the ET-8-Photo,


Source: forum.nasaspaceflight.com (Jester)


also on this photo of ET-129 (STS-126) at first glance the obliquely rising CT part (red arrow) in front of the middle strut seems to be lower than the horizontal part (yellow arrow) behind the strut. up045518.gif


Source: NASA


And also on this great photo of DaveS it looks similar at first. This photo gives the widest possible insight to below the Crossbeam, where one can see the further course of the cable tray very well. up039822.gif


Source: forum.nasaspaceflight.com (DaveS)


And so my previous perception is obviously an optical illusion, as I have now recognized in the zoom, if one waits until the zoom bar disappears at the bottom of the screen. analintruder.gif 




In it one can see a dark area in the lower part of the oblique rise, which I have not recognized so far.  cant-believe-my-eyes-smiley-emoticon.gif This is evidently a dark taped area similar to that at the top of the CT bow below the plate (Part 4). smiley215.gif


It becomes even clearer if one goes to 100% zoom in full-screen mode. up046118.gif




And if one takes a closer look at this image of the ET-129, one can see the same dark lower part in the zoom. 


Source: NASA


Therefore I suppose that also the Cable Tray on the ET-8 looked exactly the same, only that one could not see the area even in the zoom, especially because it did lay completely in the dark too. rolleyes.gif




This confirms the statement of DaveS, that the Cable Trays did not change during the Shuttle Program, wherewith I now finally can go over to scratching the Part 3


In doing so, I will essentially focus on the following known images. up045518.gif


Source: NASA




All I have still to do is think about how to proceed in the most appropriate way. smiley215.gif 


In any case, I will scratch the bow and the slant as separate parts and then connect. Since the bow with 1,5 mm x 6 mm x 4 mm is relatively small, the question arises, whether I am file out the whole part, or just the actual bow (Part 3.1), and then glue on the two tiny Parts 3.2/3.3?  up047089.gif


How do you think about it? up040577.gif

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Thanks Mike for your proposal,  :worship:


Yeah, that's exactly my plan too, because it's the easier way. And for the bow I can again use my proven Balsa-aided Bending Techniquesmiley250.gif


 Therefore stay tuned.  up040577.gif

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Hello friends,


because the bow incl. the TPS Cladding on the LO2 Side compared to the one on the LH2 Side is nearly "huge", shocked.gif as can be seen here at the ET-118 (STS-115),




it would be an unnecessary and vain effort trying to file out the whole part, as for the LH2 Umbilical. smiley_worship.gif




So I'm going to bend an Evergreen profile (1 mm x 1,5 mm) again using my proven Balsa-aided Bending Technique under hot air around a Balsa stencil.  up039822.gif


For this I first printed this drawing as a template on a scale of 1:144 in order to search for a corresponding Balsa stencil for the bow,


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


and have actually found one in my Balsa collection. cool.gif One only has to keep in mind that the Cable tray in the drawing has no TPS cladding nono.gif and is therefore a bit thinner than in reality. 




And then it went to the Balsa-bending table, on which the rectangular profile was clamped in a known manner between two small Balsa boards.




Thereafter, the Hot air gun was started and the rod bent under the stream of hot air around the template, fixed immediately and once more blown on hot again.




After the bow could cool off for a while and this shape was "frozen", I removed the small board and could convince me of the success of the bend. smiley250.gif




And so I could go on, 




and have immediately marked the Length (6 mm) and the Height (4 mm) of the bow. cool.gif




Now I still have to determine the end point of the part in front of the Crossbeam. up047089.gif Then I also know how long the Part 3.4 may be and can then scratchen this. 
Anyway, I'm very satisfied so far and I hope it stays that way.   up040577.gif

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Hello everybody,


next, I've cut off the two tiny Closeouts from an Evergreen strip (0,25 mm x 1,5 mm), as well as sanded a bit,




and glued them on the bow (Part 3.1). cool.gif




With it then I have checked the arrangement of the bow together with the center support (Part 2) and the provisional Part 3.4 for which I used a Profile bar (1,5 mm x 1,5 mm),




what already looked pretty neat. 




Here's for comparison the scale drawing of this arrangement,


which I've provisionally laid on locally, in order to see if or how the size fits, which also looks quite well.  top.gif 




So far so good, but since with it neither the endpoint of the Cable Tray in front of the Crossbeam nor the length could be determined, I came up with the idea,  einfall.gif to bend a complete CT-Dummy out of a Strip (1,0 mm x 1,5 mm) and to test its location locally according to my previous measures.


After that was done in no time, speak_cool.gif  




I've marked the height up to the Umbilical plate (about 7 mm), as well as the distance to the slant (6 mm)




where I've bent it after the upper cut.




The length of the CT Dummy from the Crossbeam to the endpoint under the Umbilical plate I have measured with 11 mm.  spiegel-smilies-0002.gif




And then I've tried this dummy locally, whereby the positioning was a pretty tricky affair. eek.gif


And as one can see, the part fits quite well,




and hits roughly onto the slant of the LH2 Cable Tray below the Crossbeam, which seems quite plausible. top2.gif




With these dimensions, I can now scratch the remaining parts on both sides of the previous bow. 




That's it for today. up040577.gif

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Hello friends,


but with the attaching of further parts that's another story, which is why I've thought of everything twice again plenty, especially since it is in the combination of such filigree parts not to millimeters, but rather by decimillimeters. cant-believe-my-eyes-smiley-emoticon.gif And wether at the end the exact installation dimension of the Cable Tray would come out is more than doubtful, or but coincidence.  hmmm.gif


Therefore, one does not get along without fitting, which is why it is better to proceed step by step, i.e. scratching one part at a time and preferring to test better safe than sorry to be able still to correct in between.  top.gif


Thus, the CT-Dummy had done its duty and could be set aside. 


But already with to try on the parts one has a lot of trouble to bring these small parts into position and then measure distances, smiley_worship.gif what one can see in this image. Because in order to lay up the profile bar for the slant next to the central support, I had to put (with breath hold) a spacer in between.  analintruder.gif




Therefore, it seemed appropriate to glue first the Center support (Part 2), so as to have a fixed point for the further procedure.  up045518.gif Before that, I've placed the support several times on the outer LO2 Feedline Bracket and juggled back and forth, and finally made even smaller corrections (height/width) until I was satisfied with its position and then it could finally be glued. cool.gif




Because if the size and location of this support would not be right, would not fit the slant, as well as the subsequent bow too. rolleyes.gif




And now, by laying on of the intended Profile bar (1,5 mm x 1,5 mm), I was able to more accurately determine the required length of the Slant (Part 3.4) than before, because the support could not slip anymore. But before I shorten the rod to the final length, I may be want to make a few minor modifications. At least the lower tip of the bar under the support should become still slightly bevelled. huh.gif




In order to be able to adapt the bow with the lower Closeout to the support, I had to first shorten a bit the upper part of the bow in order to attach it to the Umbilical plate and to be able to test the position. 


And also for this a special substructure was needed to get to the appropriate height. Above the black marking, it will then go on with the Parts 4-6. top.gif




But as one can see, the front part with the Closeout fits quite well under the support, so now still only the front slant has to be made to fit. up040577.gif

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Hello everybody,

well, this slanted front part of the Cable Tray(Part 3.4) really has it in it and has almost already become to a nightmare of my sleepless nights ... schlaflos.gif

But meanwhile I'm of the opinion that one edge more or less  doesn't matter, and therefore I will be content with an approximate solution, especially since later one cannot see this part under the orbiter from the outside anyway. top.gif


The biggest difficulty in interpreting the course of the contours in the front area was this red circled notch directly under the Center support, which I have yet still decided to do, rolleyes.gif


Source: NASA


which can be clearly seen again on this image section.


Source: forum.nasaspaceflight.com (DaveS)


And in this image one can also see the front area relatively well, where I will then orient myself during scratching, up045518.gif


Source: NASA


especially since this is only a short stub of about 5 mm length anyway, as one can see here. 




For the upper closeout, I've glued a Strip (0,25 mm x 1,5 mm x 3 mm),




and the lateral closeout will follow next in a similar way, wherewith I will then content myself.   up040577.gif

Edited by spaceman
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Hello everybody,


in the meantime I have completed the remaining CT Parts (Parts 4-6) and glued the lateral edge onto the Slant (Part 3.4), that is made from Evergreen Sheet Styrene (0,13 mm), which is very thin but noticeably in contrast. top.gif


The upper Disk (Part 6) is the same size as on the other side Ø 2 mm x 0,3 mm, and for the Slant (Part 5) and the Plate (Part 4) I have each used an Evergreen strip (1 mm x 1,5 mm)




For gluing the disc on the slant, it was again fixed centrally between two steel rulers.  up045518.gif








So far, so good. cool.gif


Next, I actually wanted to glue the Slant (Part 3.4) under the Center support (Part 2). But before that I glued the two rings on the bow of the LO2 Feedline, which one can see in this photo. 


Source: NASA


For this I wrapped an Evergreen Strip (0,5 mm x 0,5 mm) around a steel rod and held it under the Hot air gun, then I've cut out two short segments, which were glued between the two Feedline Brackets, wherewith these details get done now too. speak_cool.gif 




Then the slant was glued under the Center support, which extends to the LH2 Cable Tray under the Crossbeam. And that was also the expected delicate matter both for my eagle eyes (+ Headset magnifying glass), cant-believe-my-eyes-smiley-emoticon.gif as well as for my quiet hand to place this part with the tweezers exactly as possible straightaway, what fortunately worked quite well. top.gif




After that I immediately tried on the bow and checked its position in the contact zone under the center support and to the slant, and corrected its position still minimally. huh.gif






At the rear end of the slant now this CT-bow must be glued, as well as on it the remaining CT-Parts (Parts 4-6), which hopefully still fit in between. smiley_worship.gif


Following that, I will then bend the end piece of the GO2 Press. Line also from a Nickel-silver rod (Ø 0,4 mm), which goes from the last Ice Frost Ramp up to the Umbilical plate, but for the time will being not glued. The remaining GO2 Press. Line forwards to the Intertank will then later be installed as a separate line. up040577.gif


Source: NASA


That's it for today, dear folks, and thanks for watching. up040577.gif 

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Hello friends,


after the bow has fitted quite well, I then have glued it under the center support with the front slant and aligned immediately. cool.gif






When trying on the upper assembly group Parts (4-6), I unfortunately had to realize that this was a bit too high and did not fit into the gap.  up043952.gif Therefore, the upper disc had to be removed again and the slant slightly shortened. After gluing a new disc, the group was then glued into the gap and also aligned. top.gif








Now I'm jolly glad that I also managed this tricky LO2 Umbilical, and am amazed that it  come off quite well, as I think. And since it is quite similar to the original, the considerable effort was well worth it. speak_cool.gif


Next, as already announced, I will now bend and adjust the end fitting of the GO2 Press. Line. up040577.gif 

Edited by spaceman
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