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Edmiller

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I just finished three more builds. See photos.

The first is called Aluminum Overcast. It is 100% composite except for hardware.

The airframe was made from four wraps of 5.7oz carbon fiber and one wrap of aluminized fiberglass. The fins were made from a 1/16" carbon fiber plate with on layer of 5.7 oz carbon fiber and on layer of aluminized fiberglass on each side. In my previous post about the Boyce Gemini Titan the finished fin plate can be seen in the background. The nose cone is fiberglass painted coarse silver. 29mm motor mount.

Next up is Red Thunder. 100% composite except for hardware. The airframe was made from four wraps of 5.7oz carbon fiber and one wrap of hybrid carbon fiber/red kevlar. The nose cone and tail cone made from same materials. The fins are diamond airfoil and made from the same materials. 29mm motor mount. No electronics. The logo is made from chrome tape with a red candy overcoat.

Finally is the Blue Thunder. 99% composite except for hardware and two small pieces of wood. Carbon fiber is conductive and I needed the insulating qualities of wood for the electronics. The airframe was made from four wraps of 5.7oz carbon fiber and one wrap of hybrid carbon fiber/blue kevlar. Nose cone and tail cone made from the sale materials. Diamond airfoil fins made from the same materials. 38mm motor mound. Electronics bay for dual deployment. Logo is made from chrome tape with a blue candy overcoat.

I looked into commercially available hybrid composite tubes but found that they were expensive and generally were not compatible with hobby rocket diameters. Then I would have needed custom centering rings and nose cones. So I decided to make my own.

Ed
 

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Thank you for the compliment.

It was an incredible amount work to make them look like that. That's the look that I wanted and I did whatever it took to make the dream come alive.

Ed
 
It was an incredible amount work to make them look like that.

I believe it, that efforts shows. How did you do the diamond shaped fins? Is the aluminized fiberglass also conductive? I didn't know such a material existed. The candy overcoats on the silver lettering is a really nice appearance.
 
The diamond airfoil fins were a complicated build. First, I made master patterns out of .020" thick styrene plastic. Used liquid cement. A center spline must be made to hold the two sides apart.. Then block sanded the base to make flat and square. Using liquid cement, I glued the master to a piece of .040' thick styrene for the base plate. Let dry thoroughly. The fin tip was still open so I filled the fin with WEST 105/206 epoxy. Not all at once. Too much epoxy at one time will bow out the flat sides of the master. I think I did mine in 3 steps. When filled, block sand the tip to make it square. Then a fin tab made from .125" styrene was glued in place with liquid cement. After drying, I primed , filled and sanded multiple time until it was perfect. The final sanding was with 1200 grit wet sand paper. Then two coats of gloss clear lacquer were applied to make it smooth. Then a fiberglass mold was made.

I could almost write a book about how I did everything to make the fins. In a week or two I will be submitting more articles for the Custom Shop series in Sport Rocketry. Three of them are about making fiberglass diamond airfoil fins for the latest Estes Honest John. Stay tuned. They may be in by the end of the year or early next year.

The aluminized fiberglass is probably conductive. Many dealers of composite materials have the aluminized fiberglass in stock. I bought mine from USCi .
Another source is Composite Envisions | Carbon Fiber Fabrics, Kevlar/Aramid, Zylon, Fiberglass, Carbon Fiber/Kevlar Hybrids and Carbon Fiber/Fiberglass Hybrids.
This company has a bewildering array of products.

About the candy. The fin edges and the base of the cones are done in candy . The reason, to cover up the ugly areas. Worked well.

Ed
 
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