Title: Level 3 Certification  “The Big One”
Location: H³ Workshop 1
Date: Jan 21, 2015 – Mar 13, 2016
Description: Ultimate Wildman Kit – 6in x 10.5ft fiberglass kit
Builder: Russell Hall
Project Mission Codename: H³RL3 (Rocket Level 3)
Total weight with M1830 is 49.1lb
pdf-icon-small Hall L3 Construction Package D1.8 Updated Feb 23,2016

link_small Rob’s BP Burrito

Jan 21, 2015  UPS Delivery

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Waiting for me.. in the cold.

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M1830, L990 and my daddy’s VMAX

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CTI 75mm 6G Gen2 Case..

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The Kit… before the bath…


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Bath Time

 

IMG_20150322_144710964Got my sanding face on… March 22 2105  30* out side

IMG_20150322_144733135_HDRCleaning up a centering ring
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sanding the root of a fin

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Cleaning up the booster tube

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Test dry fit

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Marking centering rings with 1 inch spacing 180* apart       March 29, 2015

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Two centering rings notched out for kelver bridle

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CA tacked the front two centering rings

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Rock-Poxey the ‘top’ of the centering rings on the motor tube

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epoxy added to the bottom of the centering ring

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First layer of Rock-Poxey down before the strap goes down.

IMG_20150401_173741949blue tap is to keep the epoxy out of the B Fin root mount

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Flip and repeat

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Making the base centering ring to mount the motor retainer to.. it’s too big 😉  April 8, 2015

IMG_20150408_183358037_HDRthe centering ring needs a 4in hole in it

IMG_20150408_190247874_HDRI used my dad’s 4in nose cone to line up the retainer to the centering ring

IMG_20150412_163804652First couple of taps for the retainer

IMG_20150414_151958967all of the taps are in, and it fits

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Marks made on the booster tube. Rail guild well mounts 3/8in holes one at 2 inches from bottom and the other at 25in from bottom. Center of pressure is at 30inches from bottom.
5/32in hole drilled 15inches from top of booster for a pressure vent hole. April 12, 2015

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Holes drilled

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Motor tube dry fit in booster tube without epoxy on the rear wood centering ring

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Rock Poxey with chipped carbon fibers for internal fillets April 21, 2015

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adding 30ml of rockpoxey mix to internal fillet between forward centering rings

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Zoomed out view

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Getting the first fin tacked on. I use the double peanut butter way of putting the rock-poxy down.  So you put a good lay on the root of the fin, put it into the rocket then pull it out, re-apply then re-insert it into the rocket. When it’s in then I use an alignment tool to get it in the right spot.  May 18, 2015

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first fin in

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fin aligned

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fin #2 buttered up May 19, 2015

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Fin #2 aligned

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Sammie supervising the project. May 19, 2015

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Fin #3 tacked down and aligned up May 20, 2105

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Adding internal fillets to the bottom of the centering ring. 12ml per hole.. should give me 24ml between each fin set.   May 24, 2015.

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let it set over night

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Inserted 15ml of epoxy mix with chipped carbon fiber on each side June 5 2015

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Sanding the inside on the nose cone June 5 2015IMG_20150605_141038607_HDR
Mix up the rockpoxy with black die for the ebay

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Making a mess with the ebay
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Getting the switch band into the right spot.. and making a mess

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Rubbing alcohol and paper towel is great for cleaning a mess…

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6 inches both ways.. with a 6 inch switch band. makes 18 inches

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Top side of the ebay.

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just messing around to see what a short stack looks like  June 7 2015

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put the rear rail guide June 17 2105

 

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getting my foam on.. 4oz of each was need in each fin space for a total of 8oz

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mix the foam up..IMG_20150617_175508511Needed more tape 🙁

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more tape needed again

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Clean up time.. Acetone to loose up the foam that came out. August 16, 2105
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It cleaned up well with some sanding

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An other side

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Taped up the holes with the tapes for the retainer, to keep the epoxy out, August 18 2015IMG_20150818_154619188
rear end of the fin can before rear centering ring with retainer screws was installed.. lots of foam.

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rear centering ring epoxied in.

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let it sit over nights.

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Fillet around the rear center ring on the outside.. I will need to sand down the motor tube to match the ring. August 22, 2105

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Measured out 14.5 inches of 1 inch kelver bridle

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kelver bridle epoxied down on the seam of the fiberglass nose cone

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Time to work on the ebay bulkheads.. these are punched for the 5/16 ubolt

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pilot hole drilled

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up sizing the hole

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Finished holes with hardware installed

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other side done

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back side of both.. they need some epoxy on the nuts to protect them and keep them from coming off.

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comparing the 3in ebay to the 6in ebay  🙂  I like it!

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Second kelver bridle epoxied in. August 23, 2015

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Moded the nose cone rings so they will fix in with the strips in the nose cone.. next to the tube that is going in for a tracking bay. August 27, 2015

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holes added to the forward centering nose cone ring for the 2part foam to get to the top of the nose cone.

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nose cone ring epoxied in and installed.

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prepping the first set of external fillets.. making a mess!

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I used a 38mm motor tube to make the fillets look pretty!!

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First side done

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And looking good!!

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Sammie inspecting the second side of external fillets September 5 2015

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She got distracted with the cats out side…

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Second side done

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I like it.. second side from the back.

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Third and final fin fillet Sep 9, 2015

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I need to sand down the motor tube, just a little bit so the motor retainer can sit flush. Sep 12, 2015

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All done…

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it’s a dirty job, but someone has got to do it.

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Lets get more work done on the nose cone, drop some expanding foam in the tip of the cone. Sep 22, 2105IMG_20150923_183553844
Insert 3in tube for tracking bay in the nose cone, epoxied the tube in place.

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Add some more foam and watch it grow . Sep 23, 2015

So, the holidays are here… now we take some time off…

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I added some tape around the edge, less mess this way.. Jan 20, 2016

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let it grow 🙂

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All full now, time to let it set and then start hacking out the extra. Jan 23, 2016

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Insert rail guide in the hole

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and screw it in, this will pull the nut and the rubber down and that will secure it down.

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Mark up the ebay for the static ports, need 4 x 0.5in holes 4.8in in separationIMG_20160123_142826762
Add the switch ports as well.. it is 1.5in from the aft side and 1.5 in form each static port.IMG_20160123_142940533_HDR
A little help getting the drill bit started

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A little help 🙂

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Start with a small hole

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A little bigger

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A little bigger
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Look at that.. 0.5 inch holes

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A little sanding to clean up the drill holes

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Got the ebay and the payload bay lined up

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Got the ebay sled cut out 4.5in x 10.75in with some 1/4 in lugs lined up

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With a little 5min west system epoxy, the sled and lugs are secured down.

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I forgot to add the holes for the deployment charge wires..  problem fixed Jan 26, 2016

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The u-blots are too long.. so they need to be shorter

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That is better

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Both side by side, with trimmed down u-blots

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I added some 5-min epoxy to cover up the sharp edges, and to keep the nuts on.

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look what came in the mail, my Big Red Bee 70cm GPS APRS unit 🙂 🙂 🙂  Jan 27, 2016

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put some 5-min epoxy on the front ebay bulk head on the MAIN side, covering up the sharp parts..

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James is inspecting the rocket as a short stack, he approves!

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Time to clean up all of the foam on the nose cone, Jan 30, 2016

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Only an hour and a half to dig out all of the extra foam.. .. ..

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dry fit, looks good

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added bolts to the centering ring to be able to hold the tracker cover down.

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5-min epoxy on the top of the bolts to keep then from moving around.

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Ready for rock poxy, and a centering ring.

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Lots of rockpoxy, mmmmm what a mess I can make.

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Ring installed, epoxy cleaned up.. let it set now..

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Work on the tracker bay, this is a look at the inside, bolt is for support and a handle on the other side.

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little 5-min to put it all together

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different angle

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Added more 5-min in to fill in the gap around the bolt

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Here is what it looks like.. got to find an other wing nut

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Time to start tapping in shear pin holes.. 3 holes around, 3inches down, 6.4in around from each other 19.25in diameter / 3 = 6.4inches.

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nose cone fitted on, with three pieces of tap to hold it in place

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Used a punch to get the hole started, keeps the drill bit from jumping around

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starter hole 1/16in hole.

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Up to tap size

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Tap it for 4-40 screws

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the shear pin fits!!

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fits here too

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Fits here too..

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looking good, how to get shear pins on the ebay to the booster tube

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Same math as the nose cone, 3 in down, 6.4in around, tape to hole the tubes while drilling

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a punch to help keep the drill bit from jumping around

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Starter hole 1/16in

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tap hole

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tap it!  4-40 again

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it fits

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Ready for deployment testing. But first we need to arm it and load it.

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going to use my CTI Pro75 3G case

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Covering the forward end of the case to create the correct volume size.

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Add stuff it in the tube..

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Need to cut the 1in shock cord in half.. 100ft total, 50ft for each deployment side.

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from paint can to paint can is 10ft, with 5 passes around equals 50 feet.IMG_20160206_141327844
And cut it.

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I used some painters masking tape to hold it all together so I could cut it.

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Time to tie the shock cord to 5/16 quick links. I do the fishing hook knot.

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three loops around then back threw the bottom hole.

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then dress it up

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then I use the painters tape to keep the tail of the knot from flapping, and to protect the cord from the ejection charges.

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Here is everything laid out, need to tie loops in for the chutes. 1/3 of the way from the nose cone on the main, and 1/3 of the way from the ebay on the drogue. 1/3 of 50ft is 16 feet.

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make a loop and pull it threw.

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ready for a chute and protector.

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3.8g of BP for the drogue test #1, goes in the glove tip, then duck tape.

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tape to hold the bp in the glove tip.

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Duck tape to hold and protect the glove tip.

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Pulled the wire threw the hole and out the side of the ebay for testing. taped up the terminals for protection during the testing.

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Main test #3

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Dog puck to protect the chuteIMG_20160206_155845060
pack the chute and the shock cord in the protector

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Add three shear pins to the top and the top is ready.

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ebay to booster tube … getting the drouge chute and the shock cord in the protector, then load that with dog parf. then add the shear pins to it.

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armed..

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got 12ft on the drogue test #1

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got 17 ft on the main test #3

 

 

Drogue Test #1 2016 02 06 – 3.4g of 4F  BP, temp was 32*

Main Test #3  2016 02 06  – 4.5g of 4F BP, temp was 32*

 

 

 

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and Sammie wins the color chose of the rocket. Berry Pink with black

 

Construction and recovery for the  Rocket have been approved. 2-20-16

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Time for primer !!!! Feb 20, 2016

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Time to let it dry, then it will be pink and black

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and down goes the pink….  Feb 28, 2016

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PINK  Let it dry for a week…

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Blank fins and two strips… March 5, 2016

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March 8, 2016 .. paw stickers added..

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March 8, 2016  starting on the battery bay on the sled..

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March 9, 2016  Bottom cover for battery bayIMG_20160309_184529010

LiPo Batteries in with a little foam to keep it from moving

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A bit more foam

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cover on

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StratoLogger mounted down.

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bottom view with all of the wires routed

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Top view… Green side is Primary and Red side is backup..  the electrical tape to a double protection to keeping the batteries in.

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March 10, 2016 Added a Big Red Bee 70cm beacon to the bottom of the ebay.

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Mounted Big Red Bee 70cm APRS GPS unit to the tracker sled for the nose cone.

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Battery is on the bottom.

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Added some decals as well.

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Main Altimeter programed

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Backup Altimeter is programed

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March 12, 2016  Big Red Bee 70cm GPS is programmed.

 

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March 13, 2016 Motor assembly time …

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Forward closer with smoke charge inserted.. lubed on the inside of the closer

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Rear retaining ring on the nozzle.. two O rings here, inside and outside of the metal ring

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front the top.. grain in then o ring, then grain then o ring then grain then o ring then grain then o ring.

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sorry is miss the photo of the forward closer and two spacers that go in the top..

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Add the AreoPack adapter system from 75mm to 98mm

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Looks like it will fit…

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and I think we are ready to FLY!!!

rocket2-small  March 19-20, 2016 Cert Weekend