L3 Build - "Bigger on the Outside" - Ultimate Wildman

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[2015-08-26]

Several McMasters worth of parts arrived today. One item was stainless 4-40 pem nuts. All have been installed on the altimeter sled. I will need a different drill bit in the future; these are slightly loose, but not enough to be of concern. Electronics fit well and just need some nylon spacers. Planned battery placement also shown.
20150826_203852.jpg20150826_203913.jpg20150826_203952.jpg

Alt bay and airframe vents are drilled and airframe screws are now countersunk.
20150826_220143.jpg

Bad news:
  • U-bolts were too wide. :facepalm: I'll either re-drill lids, find alternative ones or get some half-height nuts for the upper side and pot the back in epoxy.
  • Screws for charge posts are a bit short. :facepalm: I'll have to get longer ones.
  • Brass inserts for the 1515 rail buttons were wrong thread. :facepalm: Replace inserts or bolts.

Remaining:
  • 1515 rail buttons
  • Av bay u-bolts
  • Drill HED av bay allthread bulkhead
  • Make blank bulkhead for HED av bay
  • Install recovery system and ground test
 
[2015-08-26]

Several McMasters worth of parts arrived today. One item was stainless 4-40 pem nuts. All have been installed on the altimeter sled. I will need a different drill bit in the future; these are slightly loose, but not enough to be of concern. Electronics fit well and just need some nylon spacers. Planned battery placement also shown.
View attachment 270789View attachment 270788View attachment 270787

Alt bay and airframe vents are drilled and airframe screws are now countersunk.
View attachment 270786

Bad news:
  • U-bolts were too wide. :facepalm: I'll either re-drill lids, find alternative ones or get some half-height nuts for the upper side and pot the back in epoxy.
  • Screws for charge posts are a bit short. :facepalm: I'll have to get longer ones.
  • Brass inserts for the 1515 rail buttons were wrong thread. :facepalm: Replace inserts or bolts.

Remaining:
  • 1515 rail buttons
  • Av bay u-bolts
  • Drill HED av bay allthread bulkhead
  • Make blank bulkhead for HED av bay
  • Install recovery system and ground test

Bad News, in this instance, are the events or decisions in which we learn something new... You are on the right path, the build looks great!
 
Name Suggestion: HUGE!

That way, when you build one bigger, the name won't need changing (its follow up would need to be "BIGGER!", followed by BETTER!, STRONGER!, and FASTER! (You know you have the technology to build it :wink: )(Let's just hope they don't cost $6,000K to do.)
 
Last edited:
Bad News, in this instance, are the events or decisions in which we learn something new... You are on the right path, the build looks great!

I agree wholeheartedly; no launch-scrubbing errors occurred and these reminded me to measure twice, buy once. Just more spare hardware to throw in the box.

[2015-08-27]
No pictures tonight, but progress was made. Charge posts installed and wiring is mostly done. 1515 rail buttons are installed. Jam nuts on the upper (non load-bearing) side of the U-bolts allowed the originals to be used. The only downer there is that the hardware store didn't have them in stainless; I'll try to remember that for the next McMaster Carr order and replace them. Nylon spacers added under electronics instead of the temporary 4-40 nuts.

Remaining:
  • Finish up wiring harnesses
  • Commit to switches or twist-and-tape
  • HED bulkheads (allthread on one and blank on other)
  • Ground testing - probably on Saturday

Doug
 
[2015-08-28]
I took last night off (bit of a sinus infection), but was back at it this morning/afternoon.

[2015-08-29]
Did some work on the HED bulkheads. I will drill for all-thread and U-bolts once it has cured. Making a 6" bulkhead from G10 stock took longer than I wanted, but it turned out fine.

Finished the wiring and measured out charges for ground testing. This flight will be twist-and-tape. The possibility still exists for Schurter switch activation of electronics, but I'm fine with a bit of drag.

BP and starter, cellulose insulation, two layers of electrical tape crossing at 90 degrees and two wraps of electrical tape around the perimeter to hold everything together.
20150829_124910.jpg

I moved everything upstairs and assembled the recovery train in upper and lower halves and proceeded to move everything outside.

Warned the neighbors outside that I would be test rocket ejection and make some noise. :grin:

[My daughter later told me that the boys playing basketball in the circle jumped and stared towards the yard when the first one went off.] :wink:

Apogee primary charge (4.00 g).
[video]https://goo.gl/photos/w12BLAxP1KdtUcX88[/video]

Sufficient separation. Drogue began unfurling.
IMG_20150829_150927.jpg

Apogee backup charge (6.00 g).
[video]https://goo.gl/photos/93vexFJ8Req5HKx78[/video]

More than adequate separation. Drogue separated from chute protector
IMG_20150829_151640.jpg

Main primary charge (4.00 g).
[video]https://goo.gl/photos/cQh8b2WNxM4Aefc56[/video]

Photo not available for above video.

Main backup charge (6.00 g).
[video]https://goo.gl/photos/JpPkjWhpz29DZUip7[/video]

Main chute shroud lines clearly being pulled out.
IMG_20150829_152359.jpg

I'm leery of overly vigorous ejection events. Why spend so much time and money on electronics that minimize airframe stress and then try to blow the thing apart?

I think 4.00 g of FFFFg powder would be enough, but it didn't appear that 6.00 g was overly energetic either. Maiden flight will be 5.00 g for both apogee and main primary charges with 7.50 g for both backup charges. I reserve the right to bump the backups to 8.00 grams, but it doesn't appear to be necessary.

The HED avbay will just have all-thread and U-bolts for now; no need to add the extra weight for now. I only have to drill one for charge cups and connections; the other (no allthread) will be moved from the main avbay as needed.

Remaining
  • Drill HED bulkheads for U-bolts and allthread
  • ???Paint???

I did previously purchase the paint for this monster, and I still haven't given up the thought of finishing it out before AIRFest. There are a few other rockets that I'm working on finishing (that cost far lest $$$ to fly) before Friday morning. The good news is that I'll be shooting lacquer from an HVLP setup. Quick drying and minimal wait between coats. We'll see...

Thanks for following along. Plans are to launch the morning of September 5th. If you are at AIRFest, feel free to stop by; the THOR group is usually in the back row most of the way down.

Doug
 
I hope Saturday has some good weather, there are a bunch of big flights scheduled for that day. Good luck on your L3 flight.
I have two big rockets I'm helping the Arizona Rocketry Team fly, one or both will be ready for Saturday. I would also like to fly my Ultimate DS, but that will probably wait until Sunday. Especially since the Wildman Mega is scheduled for Saturday. Someone should add up all the motors flown, it would be phenomenal!
 
I'm not one to put much stock in the 10-day outlook, but Saturday is looking a bit better than Sunday or Monday. Fingers crossed...

Just so this is an L3 project post:

We had a small neighborhood picnic tonight. My ground testing was one of the topics of conversation (it was even better that I had my phone with the video on it). Several were impressed, but no new rocketeers, yet...

I think I'll try for painting. I don't promise an auto-body shop finish, but it should look good from launching distance. :wink:

The theme will be posted once the rocket is unveiled at AIRFest. (Assuming it is painted.)

Doug
 
Well, the TL;DR version will be forthcoming, but here's the condensed version:

Prep and assemble: slow (3+/- hours)
Up part: pretty fast: (less than a minute)
Down part: not quite as fast (about 2.5 minutes)
Walk to retrieve: pretty slow (20-ish minutes)

The wind was kindly dragging the rocket away from me. It even rubbed off all the motel room paint-job on the silver metal tip. (Don't worry, it was just Sharpie, but I was proud of it.)
IMG_20150905_170214.jpg

All in all, a nominal flight. L3 accomplished; it has been a great journey, but there is still a lot to learn...

It will be back in Argonia next year for AIRFest with paint and a "Full Gee" motor.

Doug
 
Congratulations! I was looking for you yesterday but couldn't find where you are camped. It was a zoo here. My Ultimate won't fly due to a minor glitch packing. Left my nosecone at home.:blush: But I have plenty of other rockets to fly, and one more day to fly them. I'm helping Wildman with the Mega today, but hope to get my Extreme up after his flight.
Look me up before you leave, I'm camped just South of the Wildman trailer.
 
Wayco,

I walked by your campsite several times; but nobody seemed to be around. I'm on the south end with the THOR group. Look for a bunch of easy-ups all in a group. If you get to the yellow camper, you are one site too far.

Doug
 
Well, the TL;DR version will be forthcoming, but here's the condensed version:

Prep and assemble: slow (3+/- hours)
Up part: pretty fast: (less than a minute)
Down part: not quite as fast (about 2.5 minutes)
Walk to retrieve: pretty slow (20-ish minutes)

The wind was kindly dragging the rocket away from me. It even rubbed off all the motel room paint-job on the silver metal tip. (Don't worry, it was just Sharpie, but I was proud of it.)
View attachment 271392

All in all, a nominal flight. L3 accomplished; it has been a great journey, but there is still a lot to learn...

It will be back in Argonia next year for AIRFest with paint and a "Full Gee" motor.

Doug

Fantastic build, and great flight! I hope 4 inch Wildman L3 in a few weeks is as "boring", or perhaps nominal is a better word.
 
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