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  1. #31
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    Quote Originally Posted by Rktman View Post
    Glad you could join us Eric. I'll be back on track when my epoxy clay gets here. I wanted another option for fillets because I suck using mixed epoxy. Soon as that part gets done, I'll be ready to start installing the innards. Plus there was also some other projects on the burners that I needed to get under way and finished.

    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  2. #32
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    Quote Originally Posted by Gary Byrum View Post
    Glad you could join us Eric. I'll be back on track when my epoxy clay gets here. I wanted another option for fillets because I suck using mixed epoxy. Soon as that part gets done, I'll be ready to start installing the innards. Plus there was also some other projects on the burners that I needed to get under way and finished.
    Glad to watch a master craftsman at work.
    BTW don't forget the nitrile gloves (not latex) when handling the stuff (but you prolly already knew that). I didn't know any better and found out the hard way that you can develop an allergy to epoxy.

    NAR# 103899

    "As I hurtled through space, one thought kept crossing my mind—every part of this rocket was supplied by the lowest bidder".
    — John Glenn, Jr.

  3. #33
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    After a Holiday Hiatus, I finally cleared the project mess up and got my bench rocket ready again. I bought a few things this winter to assist in building the rest of Beldar and one of them was this Fix It” epoxy putty. The fins are so close together at the root, that I wanted to avoid using the usual epoxy because it would have been a complete mess. This worked out well for the application so I’m hoping it’s good on strength. This video helped me a lot.


    The rest of the fins up against that aft CR will be glued with standard epoxy.

    Click image for larger version. 

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    I did some sanding on the nose cone and that homemade shell/hardener is proving to be quite difficult to sand smooth. Presently, I have another nose cone I’m using as a test subject for some StryoSpray coating I also purchased for this. It’ll be a finishing coat that should smooth out the surface and create a much thicker durable surface once dried. Pic to come soon after completing the 3rd application. Lastly, I did a CA coating on the remainder of the BT 101 that wasn’t shielded with the aluminum tape. I wanted to strengthen the tube interior for any heat/burn issues that may occur during ejection.

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  4. #34
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    14th July 2015
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    Randolph, NJ
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    Beldar lives, woohoo!

    Those fillets look great. I don't know how good a fillet material Fixit epoxy clay actually is, but can see how that would have been incredibly tight quarters to try to lay down liquid epoxy fillets.

    Waitin' to see the printed skin on the BT, that's gonna be a hoot.
    In progress: something completely different / recent: Accur8 Ragnarok Orbital Interceptor
    My design thread / Fleet pics /
    My OR Renderings

  5. #35
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    Quote Originally Posted by neil_w View Post
    Beldar lives, woohoo!

    Those fillets look great. I don't know how good a fillet material Fixit epoxy clay actually is, but can see how that would have been incredibly tight quarters to try to lay down liquid epoxy fillets.

    Waitin' to see the printed skin on the BT, that's gonna be a hoot.
    I was going to do a little sanding on those clay fillets just to see how that goes. But forgot. Realistically, they don't need any. I used alcohol on my finger tip and smoothed them down really nice. LW was interested in knowing more about my experience with it too. Apparently he's interested in using it as well. I did get the rest of the fins done with the 5 min epoxy tonight and got a 2nd coat on that test nose cone. I made a foam cone much like a PNC 80-K but for a BT 101. I was going to give that to LW for Cmas this year but it has a lot of unevenness where the seams are. Not my best work, but at least it'll suffice as a guinea pig.
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  6. #36
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    Quote Originally Posted by Gary Byrum View Post
    I was going to do a little sanding on those clay fillets just to see how that goes. But forgot. Realistically, they don't need any. I used alcohol on my finger tip and smoothed them down really nice. LW was interested in knowing more about my experience with it too. Apparently he's interested in using it as well. I did get the rest of the fins done with the 5 min epoxy tonight and got a 2nd coat on that test nose cone. I made a foam cone much like a PNC 80-K but for a BT 101. I was going to give that to LW for Cmas this year but it has a lot of unevenness where the seams are. Not my best work, but at least it'll suffice as a guinea pig.
    Fix It is great stuff. I like how malleable it is--far easier for repairs and fillets or for sculpting patches, transitions, etc. than regular epoxy. Dries rock hard but still sands real easy if you need to.
    NAR# 103899

    "As I hurtled through space, one thought kept crossing my mind—every part of this rocket was supplied by the lowest bidder".
    — John Glenn, Jr.

  7. #37
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    I fed the Kevlar through the ¼” round duct in the ejection chamber and attached a Quick Link. Once I dry fitted the blast plate on, I wanted to do a test deployment with a chute attached. It was easy enough to get everything in place, so I yanked the motor mount out of the BT 101 and PRESTO! That chute popped out just like I knew it would. 2 more tests on that and I was confident enough to seal the blast plate in. Set aside to dry.

    Click image for larger version. 

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    I got some modeling clay and measured about 1.5 ounces, balled it up and stuffed the nose weight hole. Laid some epoxy in and pushed my 1.5 oz lead slug in. Those heavy duty fishing weights are the cat’s a**! Set that aside to dry also.

    Next in line was attaching the second lead of Kevlar to the motor mount. At first I wasn’t sure what would serve best, until I figured on a couple zip ties. I frayed the end of the Kevlar and zip tied above it in 2 places. The frayed end was going to get epoxied on the inside of the aft CR. Once I got all pieces mounted and trimmed off the pointy bits on the cut zip ties, I laid on the epoxy. I built a glue mound on both zip locks so everything would be smooth inside and avoid snagging a chute during deployment. I may go back after it dries and do a second helping.

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  8. #38
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    Quote Originally Posted by Rktman View Post
    Fix It is great stuff. I like how malleable it is--far easier for repairs and fillets or for sculpting patches, transitions, etc. than regular epoxy. Dries rock hard but still sands real easy if you need to.
    I do want to go back and smooth my fillets now that they're dry. I have a new sanding rod drying as we speak. I usually wrap and glue sandpaper around a dowel for those.
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  9. #39
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    OK, so now I have to figure out what gets glued next. The nose cone, the 101 assembly, or the aft CR. I knew I’d need to glue the nose in first if I was going to mount the 101 assembly, but then I would have to hope and pray I got the aft CR in without going too far. Dry fitting pretty much decided on that note, so low and behold, the CR goes first. This got mounted with 30 minute epoxy and stood upright. Once it dries, I will at least be able to get an inside fillet on it if need be. I sure laid it on thick so I may not need to. I had some left over epoxy so I used it on the zip ties. I’ll go back shortly and make sure I don’t have any nefarious runs of epoxy anywhere, then since I already have a block on the lathe, maybe I’ll turn a Von Karman nose cone. It's for a plan I drew up for my Mystic Djinn. Oooooooh!!!!

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  10. #40
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    Next on the list was knocking off that lug and flushing it up to the nose cone. Mr. Dremel sho nuff came in handy for that. And a rat tail file. I thought it wise to fill around the edge just in case my poor eyes didn’t see something and left it alone for the night.

    First thing I did this evening was sanding it smooth. That worked out very well.

    Click image for larger version. 

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    Man…..I really am not good at handling more than a dab or so of epoxy. I know I must have used a ¼ cup or so in some really awkward ways. Gluing the nose cone was a snap. But when it came time to install that 101, OH LAWD! I had to get enough inside of the cone where the blast shield rests and when I started coating that 101, IT GOT EVERYWHERE!. I’m not used to gluing the outside of one of those and trying to get it inside the rocket neatly. Then there was the build-up forming around the end of it at the aft CR and I was trying to keep it from running off on the sides. Once I finally got it in there, I had to smooth out what mooshed up on the outside of the CR and even it out. With my finger of course. I really didn’t plan well enough for this installation, but I did survive it without screwing things up. Just took forever to get that stuff off my hands.

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  11. #41
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    Okie Doke! Time to see if this all fits together. And it does, except for it’s getting a little bound up. Feels like parts and pieces have swollen. I’m sure that’s not the reason, but it looks like I’ll be doing some sanding to relieve some of the tight spots. It’s not a big deal in the long run, just another little fixer I gotta tend to. Got some filler on that nose seam and that’s drying. Basically the main construction is done. Tweaks here and there and some more touch up sanding and I’ll be ready to seal those fins. Hmmmmm….what to use on that I wonder?

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  12. #42
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    16th September 2015
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    Nifty, seeing Dan Ackroyd’s goofy Beldar face flying through the air should make the epoxy-pocalypse worth all the hassle.

  13. #43
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    Quote Originally Posted by Scott_650 View Post
    Nifty, seeing Dan Ackroyd’s goofy Beldar face flying through the air should make the epoxy-pocalypse worth all the hassle.
    Really! I just hope it all hasn't been in vain. I admit, this is truly not my norm for an odd-rock and stability could seriously be an issue. On the other hand, I've seen some stupider looking rockets fly that looked like they didn't have a chance in hell.

    Dan's face on the finish is going to kill me regardless if it flies or not. It'll certainly be something to laugh about.
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  14. #44
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    7th April 2015
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    Beldar to Gary: "When my people come to colonize this planet, you will be on the protected rolls, and no harm will come to you."
    If we can't fix your brakes, we'll make your horn louder!!

  15. #45
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    Quote Originally Posted by Lugnut56 View Post
    Beldar to Gary: "When my people come to colonize this planet, you will be on the protected rolls, and no harm will come to you."
    (Bows to Lugnut Conehead) They'll need green cards.
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  16. #46
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    Quote Originally Posted by Gary Byrum View Post
    Really! I just hope it all hasn't been in vain. I admit, this is truly not my norm for an odd-rock and stability could seriously be an issue. On the other hand, I've seen some stupider looking rockets fly that looked like they didn't have a chance in hell.

    Dan's face on the finish is going to kill me regardless if it flies or not. It'll certainly be something to laugh about.
    I think if I can get a "can" of "bug spray" to fly, you can get this to fly. Your cone is a lot more aerodynamic than my nosecone is.
    Dreaming of making the rockets I dreamed of as a kid (and then some).


    NAR L1 Cert flight: Sheridan, Oregon, USA. Sept. 19, 2015. Flew Deep Space OFFl on an I357T-14A Blue Thunder

  17. #47
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    Quote Originally Posted by K'Tesh View Post
    I think if I can get a "can" of "bug spray" to fly, you can get this to fly. Your cone is a lot more aerodynamic than my nosecone is.
    And said nose cone, is hanging upside down (with airframe attached of course) awaiting it's first layer of Styrospray. WOO HOO!
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  18. #48
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    LW told me to seal those fins then sand & prime. So they got sealed Friday evening and the nose got some more sanding done. The seam is well patched at this point and I wanted to get the motor mount assembly sanded and tweaked for the extra tight fit I was getting, Finally nailed all the little problem areas and while I was fitting it in the forward section, the whole nose assembly slipped right out of my hand and hit the carpeted floor with a pretty loud “THUNK!”
    Of course I had one of those “OH S#$T” moments. Close observation revealed nary even a fracture. YEAH BUDDY!!! It was a good 4.5’ drop dead on the top of the cone too. I finished sanding all the fins and CR as well. OH, and I dressed the part while working this evening.

    Click image for larger version. 

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    Earlier in the week, I designed a hanger of sorts from one of my bar clamps so I could suspend the nose and airframe upside down for when I was ready to apply the Styrospray. This is some really good stuff to cover Styrofoam, not to mention a great number of other things. The video is a little windy so if you are interested, it shows how durable this stuff is.



    I probably wouldn’t be using this stuff except for the foam nose cone. I plan to test it on some primed balsa fins to see how slick I can make them. If I get started early enough tomorrow, I should be able to get two good coats of this stuff on.
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  19. #49
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    Where are you getting the Styrospray, what size containers does it come in and how much is it?
    If we can't fix your brakes, we'll make your horn louder!!

  20. #50
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    Quote Originally Posted by Lugnut56 View Post
    Where are you getting the Styrospray, what size containers does it come in and how much is it?
    Straight from the manufacturer. They don't use alternate sales outlets. It's a 2 qt. kit. $32.12 + Shipping 13.50 = $47.22. (larger quantities are also available)
    A bit pricey I know. For the purpose I had for it, the Styrospray 1000 was the best option. They have a lot of other blends. I recommend you visit the web site to get the whole story on this stuff. It doesn't stink, it's flexible, dries in 4-5 hours, paintable with many different types of paint. And you should prolly use some big syringes to portion out what you need. 1 to 1 ratio on the product. You can brush it on or roll it on,even pour it on if that's your set up. But it can be messy. Floods very well too. Brush strokes disappear in just a minute or two. It will run and drip so using paper underneath is necessary. They will send you a sample for the asking. Delivery time was adequate.

    Industrial Polymers, Inc.
    3250 S. Sam Houston Pkwy. E.
    Houston, Tx. 77047
    E-mail: vholaday@industrialpolymers.com
    Toll Free: 800-766-3832
    Ph: 713-943-8451 ext. 105
    Fax: 713-943-1525
    Web: www.industrialpolymers.com
    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


  21. #51
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    Wow that is interesting stuff, looks like exactly what you needed.
    In progress: something completely different / recent: Accur8 Ragnarok Orbital Interceptor
    My design thread / Fleet pics /
    My OR Renderings

  22. #52
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    I got the second coat of Styrospray on this evening, but not without having to do some sanding. Not sure why I didn’t get runs like this on the test nose cone. Fortunately it sands fairly well. One thing I’m liking is how it’s covering the slight imperfections I didn’t get sanded out beforehand. I’ll probably go with a total of 4 or 5 coats depending on the overall coverage. In the video, he uses a roller on that big balloon dog whereas I’m brushing it on. You’re supposed to be able to use them both. I may see if I still have one of those mini rollers or just go get one. I’m sure I could even out the coats better. The fins/motor mount are ready for primer next sunny day we get. The rain and humidity dominates my efforts and we’re getting a lot of it.

    Click image for larger version. 

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    Thinking outside the box is normal for me. Went inside the box once and got claustrophobic.
    Can't never did!
    Inventions weren't created by skeptics.
    There's a bright side to every screwed up week.


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