I just completed some progress on the Nose Cone.
Made from chopping a LOC Precision 2.6" Nose Cone from my Viper III, I will use a 110# cardstock transition to fuse the two pieces, but first I need to paper the bottom/shoulder portion, so that when the exact position and top dead center is achieved, the two cardstock surfaces can become one through the Miracle of super-thin CA.
After the paper transition had been made several times, in several different sizes and proportions on cheap 20# copy paper, and tried on the actual pieces, I got the size right, then traced that Payloadbay transition template onto 110# cardstock.
I say traced, because for each one that I made as a mock-up, I went through the motions of preparing them as if they were 110# cardstock, to play with my new X-Acto "Z Series" #11 blades and handle.
I can draw nice things with this one!
I recommend it.
After the transition was tacked to the top portion, I breathed on the inside of it, well after the CA had cured, like 60 minutes or more. Just a few breaths rendered the un-treated portion of the transition supple enough to be massaged into perfect round.
I sanded the edges of the paper, but that was just to clean up my blade angles.
The transition area will get a matching fiberglass transition superimposed upon it for strength, meaning no additional support on the inner walls is necessary. This will also allow for ample area to build up with putty for shaping by sanding.
Any and all nose weight that may be necessary, even if just for added safety margin, can be confined to the body of the nose cone itself, as filler, rather than a big solid chunk of epoxy and lead in the tip of the nose.
That ought to make the safety folks happy.
While it would be unexpected that the rocket might suffer an anomoly, the possibility must be prepared for, and having a model that stays stable even if something happens is a good idea. Likewise, if the nose is just plastic, lightweight glasscloth and a little bondo putty, it is more likely to shatter if it hits something solid, rather than penetrate.
In my Mindsim, the rocket hits a Bird on the way up, on a G80. The Bird becomes impaled on one or more of the boosters, and then the rocket takes an abrupt turn and does something dangerous.
Since an untested rocket of this size can in theory be quite dangerous, we will have some built in stability and safety margins that will make RSOs and Miesters everywhere happy.
I know why my building techniques make you sad, but trust me, I get it, and will not take any risks with safety of others or myself.
I don't fly at "Clubs", though I may like to some day, and I usually just have me and my Son at my launches.
It'll have a crumple zone like a car, to protect the body of the rocket.
Anyhow, on to the Pics':
