Last year I read a fabulous book called "Into the Black" by Roland White, about the Space Shuttle program. It was an amazing book and will go down as one of my all time great reads. I've always been amazed by the Space Shuttle and can just about remember watching the first flights.
Anyway, after reading the book and building a few of Bruce's Warwings, I was inspired to try and build a foam board Space Shuttle.
A few weeks ago I built a "proof of concept" model using Dollarama foam board which a few of you may have seen.
Today I went to Lowe's and bought 2 sheets of blue foam and started measuring. Here is the wing plan form cut to scale.
I plan to use a tractor prop drive with a black spinner because I want the prop wash over the control surfaces.
Let's see how it goes.....
Due to my predisposition to Blue Foam..., I am very excited about following your project and look forward to watching the shuttles construction progress, completion and really look forward to its future flights.
I thought I would contribute to your the construction blog, in that I had taken a few pictures at this past Wednesday evening's build class where you were proceeding with working on drawing out and cutting some of the blue foam elements.
I have also given more thought to a potential propulsion system you may wish to consider using. (I would be happy collaborate on the proposed propulsion system should you wish. (Not purchasing it mind you.) Just helping to custom build one. (Refer to the last picture below.)
Just think of this shuttle flying with the propulsion system retracted and the scale space shuttle gliding down effortlessly and majestically to land on TEMAC's runway. ::)
Bruce,
It should work better than the power system my wife was suggesting for Simon's project.
Five speed and counter rotating. ;)
Frank
Well, I've done some more building/designing/planning today!
Over the past weeks I was thinking about making it an EDF model. But after looking at my 70mm Fans and the size of this model, I decided to stick with a tractor prop.
Frank tipped me off about an ME-109 spinner, which I bought. And I think it looks OK.
Today I added the center spine to the wing and have done some planning for the motor fitment. Also done some drawing to see about making the tail fin detachable, using magnets to keep it in place during flight.
Sorry I'm only building with foam!!!
The Space Shuttle is materializing! Wonderful!
Perfect nose cone/motor.
Love your drawings Simon. They remind me of Picasso!
I just bought 20 small round magnets from Lee Valley, for $15.
More progress today. Felt odd cutting the shape apart - hope I haven't ruined it!
Measured the spinner and motor and cut the nose off! :o
I then added some card as reinforcement before I add the motor mount.
Then once I'd cut some rear formers I cut the tail off! :o
I'll build a box for the tail to sit in.
Coming along great Simon. I look forward to seeing this thing go! And don't worry about making a mistake. The great thing about building is you can ALWAYS fix it. I am living proof of that rule.
More progress at NASA over the last week, with the Space Shuttle Orbiter!
It's a funny build. The idea and concept was very clear but I feel that as I build one step, the next 2 or 3 are clear but they uncover challenges or questions about how to achieve the end result. For example, I knew how I was going to do the booster pods at the rear, but now the frame is built for them to mount to, I wonder how to do the sides. And then, even with the sides, I'm wondering about which of several options is the best way to get the cargo bay door curve!
Anyway, the steps I have progressed are:
The tail has been reinforced with carbon and modge podge hardener.
The tail slot has been built.
The angled booster pod mounting has been added at the rear.
The wooden motor mount has been added, and the nose has been "layered" so I can carve the nose curves. Still more to do there.
And today the wing has been reinforced with carbon.
Some days I'm happy with progress, others I feel I'm spending time making a cartoon, silly model. I'll keep going though.
Simon, looks great and I look forward to seeing it in the air. I think any of those of us who build find it is often one step forward and two back. Hmmmm, now that I have glued it, how do I get it undone to do what I should have done before I glued it?
I like to come home from work and spend a couple of hours or so working on whatever I am building. Sometimes I come up stairs and Marg says "didn't go well tonight eh"? I say, how did you know? She says she can hear parts hitting the walls. Childish, but there is a certain satisfaction for the 10 year old in me . Keep at it man.
Fantastic... Keep at it. :)
Simon, useful web for CG calculation.
http://rcwingcog.a0001.net/?i=1
FYI
Quote from: sihinch on November 24, 2018, 07:45:26 PM
Last year I read a fabulous book called "Into the Black" by Roland White, about the Space Shuttle program. It was an amazing book and will go down as one of my all time great reads. I've always been amazed by the Space Shuttle and can just about remember watching the first flights.
Anyway, after reading the book and building a few of Bruce's Warwings, I was inspired to try and build a foam board Space Shuttle.
A few weeks ago I built a "proof of concept" model using Dollarama foam board which a few of you may have seen.
Today I went to Lowe's and bought 2 sheets of blue foam and started measuring. Here is the wing plan form cut to scale.
I plan to use a tractor prop drive with a black spinner because I want the prop wash over the control surfaces.
Let's see how it goes.....
Hi everyone - I'm looking for some help please.
Is there a tool available for cutting a long foam strip so the edge has an angle? I'm taking about 3ft long.
Like this...
@sihinch When I cut an angle into blue foam or other type of foam, I use a fine point pen, ruler, sharp knife and a sanding block to finish off the angle as desired.
At the edge of the foam where I wish to cut off the strip to make the desired angle, I draw a line on one side of the foam defining the extent of the angle where the foam will be trimmed off from the defining line on top of the foam to the edge of the bottom of the foam.
Due to the nature of half inch foam and the quality of knife used will in most instances not allow you to trim off the foam in one cutting sweep. So I will shave off the strip using the defining line at the top and the bottom of the foam as my guide for trimming the foam. Once most of the foam is trimmed away, I then clean up the angle by sanding it smooth along the length of the cut. I like to use a combination of my Dura-grit sanding/file and a good sanding block.
It works for me and doesn't take that long to do it. Avoid cutting too deeply into the foam.
There may be a tool that others may have or another way of doing it, but this works for me, while using the tools I have readily at hand.
I also wish to add that for the strongest bond for blue foam, I find that Gorilla Glue and its expanding action using moisture per the manufacturers instructions works best for me where the exposed foam joint is not going to be a visual problem. The expanding foam glue fills in spaces where the joined pieces may not abut perfectly.
With blue or pink foam you can also use sandpaper. If you want to do sand a long section, make a sanding block with a long piece of wood and use a roll of sandpaper that you either staple of use a tacky spray glue. A long sanding block makes a more even "cut" for long material
Simon,
I have a tool can cut the foam, but not sure it can help you.
Quote from: sihinch on January 13, 2019, 09:40:11 AM
Hi everyone - I'm looking for some help please.
Is there a tool available for cutting a long foam strip so the edge has an angle? I'm taking about 3ft long.
Like this...
Thanks for your advice Bruce and Stephan, and your offer of tools Alex. In the end I did it manually, as Bruce suggested, using the (amazing and brilliant) DuraGRIT sanding tool!
So here is the result! Formers and side added to one side! Booster pod ready to be sanded.
It's coming on!
oh wow... will those payload doors be operational?
Here's my answer Greg...
https://youtu.be/UIUdyBG_DT0
I've been quietly making more progress on the Space Shuttle. Again, some days I am happy with how it is coming along and others I worry that it won't fly!
I showed Arden at A&J the photo and he said "oh wow, little wing. I hope it will be stable!?" That was inspiring. So I added an EagleTree Guardian gyro.
So, the progress - hinges and control horns added to the elevons, servos are in, motor is mounted, ESC is wired up, both sides have been added, the inner bulkheads have been cut for wire runs, the nose sides are on and I've also cut the 2 angled side pieces.
I also weighed it - so far, with all electronics except battery, it weighs 2lbs without the tail, top doors, booster pods and elevons.
If build a similar plane and power by 2 70MM EDF, it will be interesting.
Quote from: sihinch on February 27, 2019, 11:13:15 AM
I've been quietly making more progress on the Space Shuttle. Again, some days I am happy with how it is coming along and others I worry that it won't fly!
I showed Arden at A&J the photo and he said "oh wow, little wing. I hope it will be stable!?" That was inspiring. So I added an EagleTree Guardian gyro.
So, the progress - hinges and control horns added to the elevons, servos are in, motor is mounted, ESC is wired up, both sides have been added, the inner bulkheads have been cut for wire runs, the nose sides are on and I've also cut the 2 angled side pieces.
I also weighed it - so far, with all electronics except battery, it weighs 2lbs without the tail, top doors, booster pods and elevons.
@sihinch Looking great. Really coming along.
I found the video informative yet ambiguous.
But the question remains, will the pay load doors be operational? If they aren't operational, then what are you going to be hiding inside the shuttle?
By the way, respecting your concerns about the outcome of your efforts; I know for a fact that with your piloting skills and when this magnificent space shuttle is completed,
it will fly.
The real question you should be asking is, how far, or for how long?
(Sorry Simon, never admit to having doubts about the flying ability of the craft you are building, or there are consequences.)
That gives me an idea ::), let's start a pool. Everyone can participate. Think of the anticipation and excitement.
Well it's been some time since I updated the thread here, and I've actually done quite a lot of work. In fact, it's nearly finished.
I've glued in the elevons and used a Frank tip to put Vaseline on the hinges before epoxying them in place. I then tested the servos and gyro function (I'm using an EagleTree Guardian for the first time.)
I glued on the booster pods by the tail and started to blend them in the fuselage.
I added a base coat of white to the top, and black to the bottom of the aircraft. After seeing some of the lines that were visible I did a little more sanding and filling, and re-coated in white.
I cut the battery hatch in the side of the fuselage and added magnets to it.
So, what's left?
I need to balance and add velcro to hold the battery (CG is just ahead of where the battery is going, so that will be fine.)
I want to spray the whole model with white enamel once it's a bit warmer outside.
I then need to paint the details (like nose, windows, leading edge, tail fin etc) and
Print some decals. I will be using "Endeavour" as my chosen Shuttle - partly because I love the TV show, and also because this has been my first scratch built endeavour!
And a great Endeavour it is. I can't wait to see it fly... ;D
Latest update: even though the foam was coated with Mod Podge Hard Coat, the tail didn't like the enamel spray paint. It wasn't damaged but there were small signs of protest. So back to cheap acrylic......
A bit more painting has taken place and it's now starting to look more like the Orbiter.
That's really looking good.
Looking great Simon. The warwing inspired projects are coming to completion.
I am excited to see yours and my WW inspired aircraft in the air.
:)
Looks like TEMAC Space program is 3 2 1 liftoff ...
Home made decals worked out well!
The home made decals and finish look fantastic.
The forward thrusters are hardly noticeable and when activated will become invisible.
Any idea as to when you plan to maiden it?
Looks great Simon.
Well it won't be ready for this Wednesday, and this weekend I can't fly.
So maybe Wed 15th May? Or at Jets Day on Sunday 19th May.
VERY cool, Simon. It's amazing how you've evolved that build concept!
It'll be so cool in the air.
Will there be enough thrust for a vertical take-off?
Very nice build, Simon! Thanks for sharing. How do you make home made decals?
I print them on this paper using a regular ink jet printer and then spray them with clear lacquer.
Hayes Paper, Waterslide Decal Paper Inkjet Clear 20 Sheets Premium Water-Slide Transfer Transparent Printable Water Slide Decals A4 Size https://www.amazon.ca/dp/B077TMFVL9/ref=cm_sw_r_cp_api_i_upb2CbX4HBG6X
There's clear or white paper. For things like US flags or the Canadian flag, you need a white background.
Endeavour is balanced and ready to fly!
I will bring it on Wednesday to training night.
Rain date will be Jets Day, next Sunday.
Simon, I can't wait to watch it take off from the Cape.
I'm sure many more will be coming out to witness it. T - 10-9-8... :)
Bruce:
re: "I'm sure many more will be coming out to witness it. T - 10-9-8... :)"
I will be there to count down past 8. This is going to take all the gray matter we can muster. ;)
Should be a fun maiden. Best looking insulation project.
Frank
Quote from: Frank v B on May 12, 2019, 03:47:24 PM
Bruce:
re: "I'm sure many more will be coming out to witness it. T - 10-9-8... :)"
I will be there to count down past 8. This is going to take all the gray matter we can muster. ;)
Should be a fun maiden. Best looking insulation project.
Frank
Yellow matter custard?
We had lift-off!!
The maiden flight took place today at Rogo Field. Scary awesome but Simon managed to trim it out and land it in one piece. A great project.
Frank
It did fly wonderfully. It truly looked like the actual space shuttle soaring by... I loved it. :)
If you want to see a terrible video taken by yours truly, go to Facebook.
Quote from: bweaver on May 15, 2019, 09:12:28 PM
It did fly wonderfully.
Glad to hear. Sorry I missed it.
Well it certainly flew and came down in 1 piece but it was quite possibly the flight I've enjoyed the least!!!
Why? It was a handful. It was super sensitive in the roll, and took quite some time to get trimmed. And the gyro I had in there was not calibrated accurately for level flight so I couldn't turn it on. And it needed full throttle to fly with any kind of authority.
Unfortunately, just as I was getting the hang of it, I lost motor power and had to do a downwind deadstick landing. It came down Ok in the field with minimal "re-entry" damage.
After flight inspection identified some cracks in the vertical fin, despite 5 carbon rods. Need to fiberglass it, I think.
When I tried to go for a second flight the motor didn't want to turn and I got a funny smell. Since NASA is so strict about safety I aborted the mission and returned the Orbiter to Space Dock.
When I removed and inspected the motor at home, I found the red motor wire had burned through. So I fried the (brand new) motor. Not sure why, maybe Frank read the power stats wrong!!!!! After the flight, if I can find one, I would ideally get a lower kV motor and try a prop with more thrust (and less pitch.)
So, she will fly again, but it will be a while.
Quote from: Frank v B on May 15, 2019, 08:30:05 PM
We had lift-off!!
The maiden flight took place today at Rogo Field. Scary awesome but Simon managed to trim it out and land it in one piece. A great project.
Frank
Hi
@sihinch ! Congrats on the maiden. The Shuttle looks fantastic, especially the heat shield!! :D
Best of luck on the refurb mission.
Andy
Simon,
What motor did you use on the first flight?
Frank
I used a Turnigy D3548 790kV motor on 4S with a 12x6 prop. I checked the stats and it should have been fine. So maybe I got a bad motor or had too little cooling.
As luck would have it, I have an old D3548 exactly the same, so will work on putting that in and adding some cooling. I may then go 3S and put a 14" or 15" prop on. That should also be fine.
So she may be back in the air sooner than expected. Just need to work out how to get to the ESC!!!! I will take Bruce's advice and cut a hole in the bottom.
Great flight yesterday for Endeavour after a few little tweaks. The main thing was the adjustment to the rudder - flies straight and level with about 1" right rudder! :o
Fantastic Simon - congratulations on your flight!
This project is NASA approved
That's both funny and means a lot!
You were the inspiration for this build Ben!