Tube Joining

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Lining it up  
bulletThe booster tube, main coupler, and the payload section were test fit together.
bulletThen the 60 (yes, I said sixty) screws were turned into the booster to coupler joint.  I ended up with sixty screws because I had 12 ribs.  In looking at it three screws per rib seemed a little weak, so two more looked like a really good strong connection. 5 times 12 equals 60.
bulletFunny how things get out of control.

Gap removal

bulletWhen the tube were fit together there was a small gap.
bulletThis gap was removed after about an entire afternoon of intense labor.  If there was ever a step that could blow out your sprocket...this was it.
bulletThe process was: Mark the area to shave down, pull the 65 pound payload tube off, sand down the ridge, heft the tube into position, wiggle it into place, and check the gap again.
bulletRepeat as needed (about 15 times).
bulletWith the ends of the tubes trimmed it was time to epoxy the coupler into the payload section.
bulletGenerous amounts of thin epoxy were painted onto the inside of the payload and onto the coupler tube.
bulletThis was gone over with a large amount of thickened epoxy to fill any gaps.
bulletThe tubes were butted together and a layer of tape was used to keep them from creeping apart.





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THE BLACK BRANT PROJECT on the verge of insanity