Pictoral build thread--Wildman Darkstar Extreme

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Viperfixr

Born Again Rocketeer
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If you are interested in yet another build thread, this one is for a Wildman Darkstar Extreme than I hope to fly it's first flight at the Tripoli Vegas Oktoberfest launch (which is actually in October, unlike the beer fest in Germany) on a L900 Dark Matter. I've also requested the help of two TAPs *in case* I'd like to try for that L3 afterwards, perhaps the Springfest 2014 launch.

The gallery link with all of the pictures and notes can be found here.

So far, the motor mount is in and the first fin went on today. This Darkstar will be built mostly stock with the following 'extras': GLR Fireball for the lower recovery harness, an SCP thrust plate (red, of course) and SCP airfoil 10/10 rail buttons. i am still deciding what electronics to put into it; will put in a beta Maras54 Lite if ready along with a Raven2 in a Power Perch, but may have to go with another altimeter if the Marsa54L isn't ready yet.
 
Don't you have to have all aspects planned ahead for a level three certification attempt? Or is Tripoli far less stringent than NAR? Great rocket by the way, I love mine.
 
I fly my DSE with 2 Perfect Flight Stratologger's. I have 3 M flights and 1 L fight and they have worked very well. There simple and very easy to use. I do also like the Adept line of altimeters.
gp
 
First and most aft centering ring goes on...will become the attach point for the SCP thrust plate. I am using Aeropoxy ES6209 structural epoxy for the majority of this build; I am used to using it and it's very strong.
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Detail of the most aft centering ring with the 8-32 nuts epoxied on the backside for the thrust plate installation.
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And the motor retainer on top of the thrust plate
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Remaining centering rings installed and spaced out. Top two rings are the same space apart as the aft fins, and the same for the bottom two centering rings and the forward fins. Top two rings are 1/4" wood, bought separately, to allow for a threaded insert for the forward rail button. With the thrust plate taking all of the motor's power and transmitting it directly to the bottom of the airframe, these rings are really for proper spacing than anything else.
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Showing the recovery harness installation
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Scuffed up inside airframe before motor mount installation. It was all 'dull' looking when I got done--all the shinny potions were gone.
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Most forward centering ring after motor mount installation, looking down the airframe (took 15 grams of epoxy!)
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Motor mount installed!
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The centering rings were spaced such that there's a ring just in front and in back of each fin, making the injection process easier down the road (sealed areas).
 
I used a lock nut for the rail button, but had to dremel it some to make room for the thrust plate. Also, luckily the screws for the thrust plate are just enough off the middle point where the rail button is not in conflict.
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Used Vasoline to protect the thrust plate screws while epoxying the aft centering ring and rail button lock nut in place--worked out perfectly.
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Forward fin after airfoil shaping and prep mounting. Note the notches put into the bottom for added epoxy adhesion surface area.
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Fin shaping detail--done with a dremel and a T-shape w/sandpaper (turned out real well).
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Injection holes drilled for forward the aft fins & centering rings. Someone may point out that they are not perfectly aligned; they don't have to be.
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Fin guides, printed from Payloadbay.com, spray adhesive on the backside, then mounted on posterboard (foam). I don't know who runs Payloadbay.com, but I use this tool with most of my HPR builds--THANK YOU for that service to the community.
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First fin on! Aeropoxy ES6209 used with a generous amount of milled fiber.
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I fly my DSE with 2 Perfect Flight Stratologger's. I have 3 M flights and 1 L fight and they have worked very well. There simple and very easy to use. I do also like the Adept line of altimeters.
gp

I've used the Stratologger in two other rockets and I like that altimeter a lot. I am debating between waiting for the Marsa54 Lite Beta test, using the Stratologger again, trying to find the currently out-of-stock-everywhere Missile Works RRC3 or using the extra Adept 22 I have lying around.

I'd go with the RRC3 if I could buy one, just to try it out, but I cannot find it in stock anywhere. The Adept doesn't lend itself to being a backup altimeter very well--no options in that regard. Might need to be the Stratologger. I'd *really* like to put that Marsa54 Lite in there with that cool LCD screen, but don't know if it will be ready in time.
 
I've used the Stratologger in two other rockets and I like that altimeter a lot. I am debating between waiting for the Marsa54 Lite Beta test, using the Stratologger again, trying to find the currently out-of-stock-everywhere Missile Works RRC3 or using the extra Adept 22 I have lying around.

I'd go with the RRC3 if I could buy one, just to try it out, but I cannot find it in stock anywhere. The Adept doesn't lend itself to being a backup altimeter very well--no options in that regard. Might need to be the Stratologger. I'd *really* like to put that Marsa54 Lite in there with that cool LCD screen, but don't know if it will be ready in time.

LOC precision had a couple last Thursday , asked when I checked stock on the usb io cable.

Kenny
 
And, my favorite part of a build...the fins go on!
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Used tongue depressors to align the front and aft fins, doubled up w/epoxy. Also used a pinch of powdered graphite in the Aeropoxy so it's easier to see how the epoxy settles on the fin root (via flashlight outside, looking inside the motor mount).
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All six are on!
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Forward SCP rail button installed via Doghouse Rocketry threaded inserts & installation tool into the forward ply centering ring.
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Injection, then fillet, wash/rinse/repeat x3.
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Detail on the fillets
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Detail on injections after drying. Injection epoxy was US Composites (like West Sys) colored with a pinch of graphite for visibility.
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Av-bay ring installed, av-bay lids doubled up
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U-bolts (1/4-20) installed in av-bay lids, sled cut out from 1/16" electrically insulative FG sheet (via McMaster), threaded rod guides via Aerotech motor kits (those ones that carry the ignitors).
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Not sure if anyone is actually reading this thread, but what the heck...I am posting anyway!

Created a mini-sled for the Featherweight Power Perch and Raven; now I can move the whole thing with three screws.
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Av-bay mount to the upper airframe via four 8-32 PEM nuts and screws
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This is where the Featherweight screw switch will go
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And, fill, sand, fill, sand...
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I'm reading this thread as well,,,,,,,,,,,,,
Solid build Mark..........

Teddy
 
I'm reading it as well!

Very nice clean build. You seem to be one of those few who have mastered the art of not getting epoxy everywhere.
 
I'm reading it as well!

Very nice clean build. You seem to be one of those few who have mastered the art of not getting epoxy everywhere.

I am not sure I'd give so much credit...I am also the one who gets to edit/crop my own photos! Ask me how I got epoxy on my Olympus EM-5 camera with a Panny/Leica 25mm/f1.4 lens (read: expensive) on it :blush:. Luckily, came right off. However, it did *not* come out of the new Fordham University t-shirt my daughter just proudly sent me (that I promply put on to show her via Skype, then went to work in the Man Cave...egad, bad Dad).
 
I am not sure I'd give so much credit...I am also the one who gets to edit/crop my own photos! Ask me how I got epoxy on my Olympus EM-5 camera with a Panny/Leica 25mm/f1.4 lens (read: expensive) on it :blush:. Luckily, came right off. However, it did *not* come out of the new Fordham University t-shirt my daughter just proudly sent me (that I promply put on to show her via Skype, then went to work in the Man Cave...egad, bad Dad).

How'd you get epoxy on your E-M5 and Panaleica 25/1.4?
 
Not sure if anyone is actually reading this thread

Enjoying the pictorial!:D

One of these days I will actually get around to building some of the multitudes of kits I have accumulated!:eyeroll:

Someday...

Carry on..Need more 'eye candy'!:wink:
 
Huge thanks to Jim Amos at Missile Works...USPS sent the package to Montana vs Las Vegas, and he flight followed the package and worked with his local Post Office to reroute the new RRC3 to me, and here it is in all it's powered up glory!
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Plus, you just CANNOT get that awesome RRC3 without the modular LCD screen and USB dongle
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Following the thread started by a TRF member called onebadhawk (aka Teddy), I've acquired these *beautiful* recovery harnesses--the first one is nylon covered in Kevlar for a good stretch for protection and the others are Kevlar. All have sewn loops that will never come undone. Awesome customer service...highly recommended!
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The other av-bay components arrived as well...will mount these this weekend. I am using Doghouse Rocketry PVC 3gr charge wells on the main side (where they will not impact the dry lake bed with the weight of the upper assembly above them) and Blastcap medium charge wells on the apogee side where the AL is needed--both primary and backup.
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Took the nosecone coupler and turned it into a av-bay for trackers. Darn thing is so large that I could fit a dozen trackers in there, even with two 1/4" all-threads running through it. I'll make a sled for taping the trackers onto as well.
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And the coupler/nosecone drying in my vise (which I got recently and find it is SO useful...not sure how I got along without one before)
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I'd *really* like to put that Marsa54 Lite in there with that cool LCD screen, but don't know if it will be ready in time.

It's ready. Making 10 or so this weekend.
 
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Have not gotten as much done as I would like, but progress continues.

Av-Bay is done--lines laid down, secured with hot glue and tested for continuity at each terminal block. Each altimeter was hooked up to the computer and settings made/double checked (as written on the tape). Both are so easy to adjust, it took all of 10 minutes for both, and that's with never having messed with an RRC3 before. Here is the RRC3 and the Raven (respectively):
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Alignment for the RRC3's screw switch is right on...I hate digging for the switch at the pad
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Apogee end
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Main end...spider web-like stuff is hot glue that I have not trimmed up, which I used to secure things from moving around and to plug lid holes
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The main screw switch is a .25" hole, and my Missileworks manual said I needed .325" for a single vent hole with this 3.9" diameter x 11" long av-bay. So, I twice drilled 120 degrees off from the screw switch with .0825 holes, for a total of 0.415" total vent hole area--should be more than enough.
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And, now the recovery side is here...enter the Wildman Recon 60" chute, rated up to 21lbs
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Plus, I like drogue chutes--keeps things orderly on the way down and makes sure the main doesn't get fouled on deployment. I'll hook this up at the lower av-bay end to keep the main parachute well above and pointed away from the large & heavy lower airframe (that should be 30' below it)
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Ground testing next weekend.
 
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Ground testing done. Drogue will be 3.5gr of 4F with a backup of 5gr. Main is 3gr for the primary and backup (that's all the charge well will take...should have gotten the next size up for the backup to have extra oompfh).

Here is the layout after the test, untouched
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And here is the ground test itself. First test at 2.5gr sheared the 3x 2-56 nylon shear pins and knocked the nosecone off, but the chute got stuck half-way out. The second test at 3gr looked much better, and with the redundancy of the second charge to ensure half-way deployments get all the way out, I think I am good.
[video=youtube_share;cG0giW5wfTo]https://youtu.be/cG0giW5wfTo[/video]

Now for the painting and sanding that I detest so much. Would you all rather see a Red/White/Blue paint scheme named "Jihad This!", or the typical Darkstar paint scheme and decals? Here is what the "Jihad This!" idea would look like...
m+rose.jpg
 
On second thought, I am going to upgrade one of the two main charge wells to a 6gr version from Doghouse Rocketry and up the main backup charge to 4gr, just for that added bit of insurance. Primary will remain 3gr since that seemed to work just fine. There isn't a lot of room for the 60" chute, so it's a tight fit--and a higher charge than I am used to seeing for a 4" rocket.

BTW, I unfolded the Wildman Recon 60" chute for the first time today and at CJ's suggestion took pictures as I did so. Since the way the chute arrived is about as small as I can expect it to ever be, I've preserved the HOW of folding it into as small a space as possible. I might even put together a instruction guide via pictures just to help future packing. I've only got a couple inches in the main section to spare, from what I can tell. Turning the nosecone into an av-bay has it's downsides, but this is going to work fine anyway.

Being that this is my first Wildman branded chute, these Recon chutes are NICE! I was on the fence as to what chute to get, and I should not have been. This Recon chute strikes me as a better Skyangle--construction and materials are top notch--maybe the best I've ever seen. It packs down well despite it's size and heavy duty materials, too. I've got a Skyangle 48", and this one seems stronger and easier to pack. Swivel at the end of a braided nylon line as well. I'll be buying more of these for sure.
 
Ref above question about what decal set to go with, I went with the "Jihad This!" idea, picture above. Painting in progress.

Now for the painting and sanding that I detest so much. Would you all rather see a Red/White/Blue paint scheme named "Jihad This!", or the typical Darkstar paint scheme and decals? Here is what the "Jihad This!" idea would look like...
View attachment 147381

I am leaving this Thursday AM to go visit my oldest daughter at Fordham University--Parent/Student weekend. I cannot believe I am old enough to be the one *visiting* a child in college...ugh. Needless to say, no more progress updates for a week+.
 
I think I am about done...time to build motors and send this rocket on its first flight next weekend! I am giddy with excitement. Instead of multiple flights, I am thinking it's first flight will be on a L900 Dark Matter. I've never flown an L motor, let alone a sparky one. I cannot wait!

The basic idea for "Jihad This!" came to me while thinking endlessly about rocketry in Pakistan last year. I contacted Mark Hayes at Stickershock23 and he made the idea a real design, and showed great patience with me as I tinkered with the concept. I almost painted it as a 'basic' Darkstar just to keep things simple. If I had not daydreamed of this rocket for a year+, I would have taken the simpler route. So much for simple!

Here she is in all her glory...what do you all think?
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How does,,,,,,,,,,,

Unbelievable,,,,,,,,,
Smokin,,,,,,,,,
Gorgeous,,,,,,,,,,
Insane,,,,,,,,,,,,,,

Sound ?????????????

Teddy
 
Hey Mark,,,,,,,,,,

Isn't Mark from Stickershock unreal to work with..........
He will not rest until your almost jumping up and down happy with the proposed design........
To the point that you think your torturing him,,,,,,,,
but your not,,,,, he's totally OK with it,,,,,
this is what he's used to,,,, this is what he does..........

And he costs less then you'd pay for---
cans of spray paint, primer, and masking tape at home cheapo.............

Teddy
 
Mark!

All I can say is "WOW" that's one smoken DarkStar.
Best DarkStar I've seen yet, and that's a lot of them!
 
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