as205 Posted May 29, 2019 Share Posted May 29, 2019 The rocketry club I belong to, Tulsa Rocketry, started a group project a few months ago. We decided it would be good for the club to do something to commemorate the 50th anniversary of Apollo 11. We decided to build a flying model of the Saturn V. This has, of course, been done before with some commercial kits and some fantastically large scratch build rockets. We only had about 8 months to complete the project so we looked at available tube sizes and determined that a 1/48 scale Saturn V would be of a size that would be both doable and impressive. We started by gathering the tubes. The S-IC and S-II would be made from Sonotube. Those are the tubes that people use to pour concrete columns. We got some 8.25 in diameter tube cut to the length of the S-IC and S-II combined. The everything above the S-II would be from a phenolic type tube called BlueTube. We used 5.4 in for the S-IVB and 3.125 for the SM. The sizes are not exact for the scale but we didn't have time to make custom tubes that could stand up to being hurled several hundred feet into the air. We designed the rocket to have two different aft structures. One that would have oversize fins that would be for flights, and the other would be scale detailed for display use. Most of the detail parts would be 3D printed by a club member. The transitions and S-IC engine fairings would also be 3D printed. Internally there are additional tubes to support the rocket motor and provide shoulders to allow the different sections to separate at the appropriate time in flight. The first separation point is just aft of the S-II forward skirt. The next point is at just below the Instrument Unit and the final separation point is at the BPC. The CM and LES come down under a separate parachute to help mitigate any landing damage. The Sonotube is very rough and required several coats of thick primer and sanding in between to get in shape. Even so, there are a few lumps here and there. It will still build into an impressive model. The BlueTube has some spirals that have to be filled and sanded. The SM will not be filled and sanded since it will get a wrap of .015 sheet styrene. Here you see the parts assembled before any detail work has started. Here is an angle from the rear. This is also the initial balance test to verify where the center of gravity is. Note the flight aft skirt goes all the way down to the bottom of the fairings. The display aft skirt will be shorter as it is on the actual vehicle. Here we are applying contact cement prior to placing the first of the many wraps that are to go on the rocket. After letting the contact cement cure for 15 minutes or so it is time to put the first wrap on. It was a very nerve racking time since you only get one chance to place it. When the two parts touch, they are connected permanently. You can also see in this photo how the removable aft skirt works. Four all-thread ensure a secure connection. The blue tube sticking out is the motor mount tube. When the display aft skirt is put on you will not see the motor tube. Instead you will see 5 3D printed F-1 engines. Slow and steady does it. The wraps were made with .005 sheet styrene and strip stock of varying sizes and shapes according to the scale drawings from David Weeks. Here is the flight aft skirt after primer has been applied. Here is the aft end after application of more wraps and some of the 3D printed parts. Here is a photo of someone looking over the scale drawings. If you look on the left you can see a short piece of tube with a wooden bulkhead attached. That is the display aft skirt. It will be detailed out later. Here are some pictures of the 3D printed parts after they were applied to the S-IC/S-II wraps. More to come... Quote Link to post Share on other sites
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