Estes Delta Clipper upscaled build

[downhill_D]

so after losing an estes delta clipper back in the late 90’s (like many others who owned one) I just couldnt let it go...

I have upscaled a delta clipper over coffee this morning in rocksim, made fin templates and made all tube cuts and fin cuts with one 180mm japanese razor saw. This makes quick and accurate work of anything aircraft plywood.

So far:
Loc HPR tubing was used.
Loc 38mm nosecone
Body tube 38mm
Motor mount 29mm
1/8” SIG lite-ply for fins
1/4” SIG lite-ply centering rings

Everything scaled up in standard measurements using a multiplier of .496” in rocksim for my build.

I will be adding a small switchband, sled and rails for a tracker and an eggtimer classic computer I built a few months ago. This build may go a bit slow but will be worth it. Composite motor to composite motor is the plan.

 

[downhill_D]

Slotted the tubes this afternoon and trimmed and sanded the fins even. Now I just need to order some centering rings. My ability to make perfectly centered rings is far more costly in my personal frustration to make for now.

I am working on a small jig for my bench lathe to do this but they are cheap enough for now I would rather have them nice and centered and lasercut

 

[downhill_D]

38/28 mm fiber rings and plywood centering rings arrived and were fairly inexpensive. I was debating on which to use for the project but am leaning towards a multimedia approach. I know I need a channel to my second stage for the ignitor and cutting a fiber ring for this might prove to be a less than clean cut or have some loss of strength. I can file plywood rings to shape much easier, they are definitely lighter and takes up less space inside. The 1st stage (booster) also has limited space since the through the wall fins are the limit for the aft and fore centering ring space. This will prove to be a fun challenge in the build.

 

[mbeels]

Nice, so I assume the booster will be tumble recovery? Sounds like a fun project. The classic should work fine, the only downside is that it is two channels, so if you use one for airstarting, it only leaves one more for deployment. Are you doing dual deploy? You could do motor eject the drogue (or drogueless) at apogee, and the use the classic for mains.

 

[Theory]

Like this build as I really like the delta clipper.

managed to hang on to a delta clipper for a long time. Unfortunately it was “lost” (more destroyed) when it landed in a road and was run over

 

[BBowmaster]

Like this build as I really like the delta clipper.

managed to hang on to a delta clipper for a long time. Unfortunately it was “lost” (more destroyed) when it landed in a road and was run over

Perhaps you gave up too easily. My USS Atlantis had that happen. Probably added 25% to the weight in repairs that time.

 

[Theory]

Perhaps you gave up too easily. My USS Atlantis had that happen. Probably added 25% to the weight in repairs that time.

LOLz. Na it was done. 100% flat and missing a fin. Was a nice flight on a C11-7

 

[downhill_D]

Nice, so I assume the booster will be tumble recovery? Sounds like a fun project. The classic should work fine, the only downside is that it is two channels, so if you use one for airstarting, it only leaves one more for deployment. Are you doing dual deploy? You could do motor eject the drogue (or drogueless) at apogee, and the use the classic for mains.

Yes tumble recovery for the booster - I upscaled it so it should tumble like it was designed as long as I don't adjust the cg to cp relationship of the original design too much. The SIG lite-ply helps a LOT...very light stuff.

As for deployment I plan to use engine eject for the first few flights to see how it goes. I normally use JLCR even on a 38mm airframe for a "dual deploy) so I'll likely use that for the higher altitude attempts. I also should hopefully have a stratologger timer by then...I ordered one for my redundancy, they were in stock. I read about a team doing a MACH 3 attempt (I am not making any attempts other than actual stable flight) and they used two different models of electronics to prevent a failure of the same problem. That seems smart so I will use it for air start and main with timer redundancy. This computer is the first egg timer product I built-want to make sure it doesn't fail. I have used Connor normally but wanted to try making a classic kit-it was easy on this one but the others... The tracker will go into this as well...no historical repeats...I feel like ALMOST everyone has lost one due to the altitude it achieved on a D motor set...wow. This is just a little bigger Thanks for reading!

The classic computer does have an auxiliary channel but I am not sure it can be used for air starting -I am still new to these electronics.

 

[mbeels]

The classic computer does have an auxiliary channel but I am not sure it can be used for air starting -I am still new to these electronics.

Sounds like a good plan, especially with the tracker. The Classic can be used for airstarting, I've done it.

 

[downhill_D]

Finally got some progress done after slightly revamping the old. I added plywood centering rings, a tube for the igniter. I’ll attach the second set of fins tonight and be ready for decal scale up of the design. I am going to ask (very nicely) the design team to cut some vinyl they have in stock. It is close to the original orange I think. I am so happy this turned out for my first scratchbuilt 2 stager. You will notice I used a bluetube av bay. I needed simplicity and was making an order. However their 38mm plywood was shorter than even a regular egg timer with antenna so I did modify and make my own from more SIG lite ply. Love that stuff...so light. Anyway it is a tad longer than original scale.

 

[downhill_D]

The bay and the final scratch build ready for weighing etc for rocksim to narrow down my best motor choices. Plus rocksim just upgraded to a new version - cool timing!

 

[downhill_D]

Starting to look like the delta clipper...I need to get construction orange paint to finish this color scheme but it is almost done.

 

[Theory]

Well done on the build. Like that you are replicating the original color scheme

 

[downhill_D]

Well done on the build. Like that you are replicating the original color scheme

Thanks! It is a big part of what made the model so memorable-the altitude and the color scheme!

 

[downhill_D]

More color...a little more yellow then the checkerboard patterns go on.

 

[downhill_D]

Clear coating this one over the weekend, then sanding, then clear coating.

 

[downhill_D]

So I emailed back and forth with Mark (thank you Mark!) at sticker shock and it turns out they do have the delta clipper decal set available (the decal set is online now). I couldn't let this fairly decent upscale of the Estes Delta clipper go without perfect matching decals...photos to post when it is done. Until then I will work on BP motor options for first flights in simulation.

 

[downhill_D]

Stickershock decals showed up (very quickly) and they are awesome with vinyl work! Highly recommend their work! Precise! The first few have gone on flawlessly. I will definitely do custom work with them in the future. I also bought a set of cg/cp stickers (they also come in colors)...adds a very professional touch compared to my sharpie versions.

 

[downhill_D]

I will clear coat these once done.

 

[downhill_D]

One more coat or two of clearcoat and it is ready for packing and weighing. Stickershock is really good with multi color vinyl! Wow! The wrap matched perfectly! Just awesome:

 

[downhill_D]

so my RockSim abilities are okay and it seems I forgot to use the dropdown menu for designating 2 stage where you can choose Barrowman or rocksim math for simulation..this explains all the flight fails in simulation...it never separated in flight. :/ I am not sure there is a quick fix and may have to rebuild the rocket on a new file. At least I have all my measurements beforehand. Looking forward to ordering the correct motor combo before 1st flight...possibly a month away.