Tag Archives: rockets

Shop Makover – First phase completed!

Starting Point

I purchased the house in January 2007. I took this picture on the night I received the keys. The garage looks pretty big in this photo. And in fact it is a nice decent sized tandem garage. Nothing was painted at that point. As you can see, the rear wall is cement.

The way it looked when I bought the home.
The way it looked when I bought the home.

The first thing I did, before moving anything into the shop was to start priming the walls. Being anxious to get out of the projects I was temporarily renting, I decided that I’d primed enough to move in my junk. And to a large degree junk it is.

The garage remained in this state for about 1 year, before I started to empty out of my storage units and move my crap in with me.

A downward spiral of hoarding, had begun.

Shop as it looked after movin (Jan 2007).
Shop as it looked after movin (Jan 2007).

First year

Despite my best efforts of my messier side, to clutter things up. It remained pretty clean and organized for the first year following move-in. Here the walls are primed, I have my flag (it flew on my old house the morning of 9/11, I always flew a flag in front of my house), the last of my Porsches and for once very little clutter along the walls.

My old 993 in the shop.
My old 993 in the shop.

After the first 2 years, thing got rather messy

Fast forward two years (February 2009) and this is what it had all degraded too. Stuff everywhere, tools hard to find, boxes of 20 year old paperwork mixed in with cases of chemicals, car parts, books, and miscellaneous… stuff.

In this show I had actually done a significant amount of cleanup, since I was testing out the viability of converting the larger rear section of shop into a photo studio. With a pair of home-made backdrops (thanks to DIY Photography website), and inexpensive halogen lighting it actually worked!

The floor is wet because I mop it from time to time, to keep the concrete dust manageable. It’s really bad. Not sure whey it seems to power up so much. Cars and motorcycles maybe? Don’t know, but it’s less than ideal!
ShopStart01

I’d also painted the wall above the garage door, and the stairwell entry. It was a blue I picked up at the store for $5.00 a gallon. Pretty good deal. And it’s really a nice blue. But.. not for the shop. I never finished the cut-in because I was not sure I wanted to keep it blue.

It was not a tough decision to change it, but I didn’t know what I wanted to change it too. White was too boring, dark blue was too dark. So it stayed in that condition until November 2009 when I finally decided on a color that worked for me.

Another one of the steps in the process, was to sell the beast of a motorcycle seen here. It was my KTM 950 Adventure S. A kick-ass machine, but one I seldom used. Basically it was just losing value and I had a fair bit of cash tied up in it. Selling it alone freed up a much of space in the shop.
ShopStart02

Underway

Sometimes you have to make a HUGE mess, to start cleaning things up.

This is about 1/3 of the way into the project. By this time I had applied some white cement paint (high traffic formula), taken apart, moved and re-assembled my workbench.

One of the desires I’ve had for years, was to find a way to put my toolbox ‘inside’ the workbench. This does two things for me. One, uses up less wall space. Two, it’s one less flat surface I’m inclined to stack junk on. I’m not the cleanest person by far, but if I put some logistic limitations on myself, I can remain fairly neat and organized. One just has to come to terms with one’s eccentricities and limitations.

Getting my Snap-On toolbox under the bench required a permanent modification to the bench itself. It also required that I remove the wheels from the base of the toolbox so that it would ‘slide’ under the benchtop without me cutting the bench top supports. It’s FAR easier said than done. Removing the wheels was easy. Wrestling the box up inside the confines of the workbench took about 30 minutes.
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Storage racks cleared, boxes opened and inventoried, you name it. The process was getting to be pretty intense. At this point piles of things were being relocated in groups around the shop, in order to gain access for painting or cleaning of other spots of the shop.

A failed attempt at application of a red stripe between the grey and white resulted in the rough line seen there. The ‘maximum application time’ suggested for painter’s easy release tape is, as I find in a lot of things (like the weight rating of cheap ladders), actually has some relevance. In this case it’s 2 weeks. And in my case, I left it on longer than that, over-painting the bad Red gloss paint. The Red under the white primer is no longer visible, after countless coats. The buildup of paint on the wall in that area is, impressive?
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After completing the upper wall repaint, I moved onto the rear wall. A lot of the junk on the floor was held by the empty shelving unit seen middle photo. Most of it was, actually. But here, things are starting to come together and I can see the light at the end of the tunnel. This is turning out to be worth all the effort.
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PAINTED!
Long shot to the back of the shop. Walls painted in the two colors and my big H&R banner hung up. It’s really huge. And it’s a nice high quality banner. However, I’m not loving it. It’s just too big.

I think I’m going to take it down for while and see how I like it without the big banner. Maybe I’ll sell it on CraigsList. Maybe I’ll toss it. Maybe I’ll store it for a future shop at some point in the, uh, future. But I’m pretty sure I’m taking it down for now, at least.
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Even the largest of my vehicles fits easily in the reconfigured shop. The proximity of the work bench could be an issue working on doors, but I still have the entire latter 1/2 of the shop I can pull the vehicle into if I need to do that work.

As shown in previous photos, I can fit two cars, three motorcycles and a fair bit of storage all in this ‘little’ shop.
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Phase 1 Completed

A place for everything, and everything in it’s place.

For the time being, the motorcycles will live along that wall. When the weather improves I plan to spread them out for easy selection.

The line between the grey and white turned out very crisp, and thanks to the use of the laser, level and very straight.

Patience pays off.

ShopMakeover01

The final result of the wall repaints. The slip cover on that couch has to go. It’s hideous. Not as hideous as the couch fabric it covers (long story there), but it just looks… bad. I think a new red one is in order. There is still too much concrete dust to use black, it would be worse that the denim blue.

Again, the upper / lower sections of the wall show a nice crisp line. Unfortunately that wall is concrete and full of imperfections. At some point I might skin it with 1/4″ sheetrock and repaint. But not this winter.
ShopMakeover02

The choice to repaint that section in the high-gloss gray enamel, made me happy. It looks nice, clean and not so depressingly dark when I walk to the shop. Plus it’s not the same boring white I could have done.

This time I cut in the corners and even painted that section of the ceiling to match. That was partially a test to see if I should paint more of the ceiling in that way. So far I really like it. Not sure how it would play out in the full garage but I’m leaning towards it pretty heavily.

Also in the photo is the aluminum later that almost killed me. Stupid thing collapsed and I fell about 4′ do the cement floor. Luckily I still had a bunch of stuff staged for donation and storage, and that ‘cushioned’ my fall. Cheap Chinese crap ladder. I’m glad I have my real American made ladder back from my friend Colleen (it does not look like it ended up in any of the photos, but I was also not trying to photograph my ladder!).

ShopMakeover03

And finally, the ‘Big Red Wall’. This is actually how the entire project started. I decided to finish painting this wall with primer, then applied the $5.00 gallon of red paint (Lowe’s Clearance Sale) and viola. I was so happy it inspired me to redo the entire shop.

In the back you can see the kickback section of wall, now painted in a sage tone green. This is the same color I painted my kitchen (another $5.00 score I had custom mixed). Frankly, most people that have seen the shop don’t understand my green wall. Tough. It’s my shop. It might see the same white-gray treatment the rest of the shop sees, but I’m going for a bit of a multi-purpose area theme. Mixed shop and video gaming man-cave (60″ plasma and network cabling to follow later).

I have a couch (that slip cover is NOT going to remain… looking for a better looking cover right now) for the space, and a pair of stacking office chairs. I’m also on the hunt for more 50’s era bar / dinner stools like I have upstairs. There is a quirky place right across the street from work that sells random stuff. Next time they get some more I’ll be in there to check them out.

Drain pipes also received a treatment of the gloss gray. I think it’s much less distracting than the black pipe covered with plaster and white paint streaks. They almost look like steel pipes (they are some sort of poly/pvc/plastic).

ShopMakeover04

The next step for me, it taking care of the floor ‘treatment’. Right now I am investigating the costs and utility of installing Martial Arts mats in the ‘pregnant’ section of the shop. The other option is the epoxy paint. Painting would have to wait for summer since it won’t cure in these temperatures.

I’m sure I’ll have more to say on the shop later.

For now, I rest.

MGR-1B Honest John Rocket Project (DD08)

Goal of this project, is to create an authentic looking model of this rocket here, the MGR-2 Honest John tactical missile.

MGR-1A  Honest John (on left)
MGR-1A Honest John (on left)
MGR-1B
MGR-1B

Second of my custom rocket construction projects. This is the also the 2nd of my semi-scale rocket builds. The first (DD05 V2) was mostly a simple modification of a single rocket kit. This project is based primarily on parts from an Estes LoadStar rocket kit, with significant modifications.

I decided to start off with the most challenging part of the build. Construction of the warhead section. The orginal real Honst John (MBG-1A and MGR-1B) had a rather unique bulged section to house the warhead. It took a few days of considering several methods of accomplishing this before it was clear that no intermediate tube was even required. Having all the parts I needed already I started the build.

Original LoadStar nose code and payload adaptor
Original LoadStar nose code and payload adaptor

Normally the parts are separated at the waist section in the middle, creating a seperate nose cone and payload adapter section. That middle part was not needed at all, and if used would have created a warhead section that looked very little like the original.  To produce the desired result, the upper and lower sections would be chemically welded together.

Nose cone and adapter sectioned.
Nose cone and adapter sectioned.

Following the fusing of two sections, fine filler was applied to all the joints and mold lines and set aside to harden.

Assembled, glued and filled warhead assembly
Assembled, glued and filled warhead assembly

After the filler dried, and finish sanding completed, the assembly has taken on the desired look.  The warhead’s boat tail is shorter on my semi-scale attempt than the real rocket.  This is an important point to consider later in the project.

Final wet sanding of the nose section.
Final wet sanding of the nose section.

Checking scale of the nose and body, compared to a good side view of the real deal.   Measuring, the photo was within 80% of the size of the final product.  Considering the boat tail on my warhead section is shorter, I adjusted the body section proportion to give me a good overall length and look.   Yes, this is a semi-scale project using off-the-shelf parts.

Double checking my scale calculations
Double checking my scale calculations

To be continued….

Construction History

11-Oct-2009
Began construction of custom warhead section from LoadStar nose and payload adapter.

12-Oct-2009
Finish sanding of the nose section. Checking scale and calculating a reasonable body tube length.

Flying fleet continues to expand

The collection of flying rockets continues to expand.

FLEET (l. to r.)  220Swift, Sprint, Fire Streak, Viking, DD05 (V2 semi-scale), Pheonix, DD06 (docked Taser w/ L.E.D. payload), Big Betty, DD07 (custom Bertha w/ payload)
FLEET (l. to r.) 220Swift, Sprint, Fire Streak, Viking, DD05 (V2), Phoenix, DD06 (Taser mod.), Big Betty, DD07 (custom)

DD05

This is a semi-custom design.  Based on an Estes Baby Bertha rocket kit.  Extended nose cone and scale V2 fins make this look similar to the world changing V2 Ballistic Missile of WWII.  Rocket was still awaiting final finish paint at time of photo.  [ Full Project Writeup ]

DD06

Design is more of a repair and subsequent enhancement of an existing rocket (Estes Taser).  Following water damage at the base of the body tube, I sectioned about 2″ from it, and re-affixed the poly engine and fin assembly.  The top red payload section is from parts ordered online.  The L.E.D. payload (for night flights) comes from Halloween skull decorations (like the white plastic skull far right).  A pair of night flights proved the rocket to be a good flyer and the lights made night recovery very easy.   Night rocket launches are fun!

DD07

Constructed completely from spare parts attached to a large Estes BT-55 body tube that I ordered online.  The fins and nose cone came the Baby Bertha kit.  Launch lug and payload section came from an Estes Payloader rocket (which was parted out for another project DD08).  Engine mount was constructed from scratch based on patterns from other kits and a home-made mild steel engine retainer clip.

Another Great Day of Flying Rockets in Bremerton

Weather was not the best this morning. Sunny but a fair bit of wind. So I ended up waiting until 16:00 to pack up 4 of the rockets and head out. We took:

Lucky for you readers, I forgot to take my camera so no video, no photos, just a quick accounting (for my records really).

We picked up 2 packs of mini-motors at the hobby shop. A set of 1/2A4-T (twice the power of the mini’s used previous in the Swift and SkyStreak), and pack of A10-PT which has A LOT more power than the 1/4A’s, something like 4 to 8x the power. We’d already had issues finding the little swift with the small motors. However it is wearing it’s new all-orange paint scheme so, I was willing to ‘risk it’.

220 Swift

Following the re-construction and repainting of the rocket, it’s nose-down descent profile does not seem to have improved. There is a certain amount of danger in one of these things coming down nose first at maximum velocity, so I’m considering permanent retirement of this specific rocket.

1/2A3-4T – (8.3 Newtons thrust) This motor has a max thrust of 8.3 Newtons, which has quite a bit more power than the engine we first used (1/4A3-3T –  4.9 Newtons).   Against a white sky, this put the high-vis mini-rocket completely out of site.   Thankfully the change to hi-vis orange was critical to use finding the rocket.  The engine ejected as designed (un-recovered) but the rocket still descended nose down.

A10-PT – (13.0 Newtons thrust) First off.  Don’t use this engine in a rocket.  It has a max thrust of 13.0 Newtons.  Plenty to get a rocket off the pad.   HOWEVER, it turns out the ‘P‘ designation means ‘plugged‘.   Plugged engines have no ejection charge.  This completely explains why the two flights we made with this motor, the rocket cam down very rapidly with engine still in the body.   There seemed to be a trace but NO ejection charge of any kind.   With that much additional thrust the little rocket was quickly out of sight!   GONE!   Hasta la Vista baby!!    Again, because of the high fis paint, I spotted the fins of the 4″ rocket sticking out of the grass about 150 yards away (thank God for my still better than 20/20 vision at age 45).   I have 2 more of these engines, not sure what I’ll do with them now. :/

Viking

First flights for this school project class rocket. This was also my daughters first rocket project! It came out great and I have to say it flew great too! This is a streamer recovery rocket, like the Hi-Flier so it can be used in smaller fields.

A8-5 – (10.7 Newtons Thrust) First flights should always be done with a smaller motor. This specific rocket does not have an engine retainer (engine ejection expected?) but also has the streamer recovery with nose-blow actuation already noted. Flight was perfect. Straight up! Most predicatable flying rocket we have right now. Engine ejected (recovered) and so did the streamer. Rocket landed close to launch location. Could not have asked for a better launch evolution.

B6-4 – (12.1 Newtons) Sure, I like to push it a bit. We were able to visually track the rocket with the A engine. Launch put the rocket out of my visual range. Again, the high-vis orange allowed a recovery. Unfortunately, this time the engine did not eject from the rocket bods and it descended a little faster than before. Upon landing the fin with launch lug attached was snapped off. They were located together so it’s very unlikely it happend during flight. Back to repair shop for this one.

Hi-Flier

Another lesson learned the hard way, camouflage paint on a rocket might ‘look’ cool but in practice it’s a real pain in but to find them once they land. One thing to note about this rocket. Fly in light wind only. the CP (Center of Pressure) is far enough behind the CG (Center of Gravity) that it windcocks like mad in even a breeze. Windcock? That means it turns upwind due to the aerodynamic pressure on the over-sized fin area. Despite directing the launch rod slightly downwind on the 2nd lauch it still curved upwind.

A8-5 (10.7 Newtons Thrust) – This rocket has been flown many times with this engine. The difference this time time? The streamer did not unravel! Perhaps having it packed in the body all week awaiting our next trip to the range formed it into a ball. Whatever the reason, the thing came down like a rock from 600+ feet, landing with nice little thud, only a few yards away. No damage noticed on vehicle. Ready to launch again.

C6-5 ( 15.3 Newtons thrust) – Why not tempt fate a bit, right? Again he rocket turned up wind. With the higher impulse engine it really REALLY took off. With the 5 second tracking trace I was able to spot it pretty easily in the sky. While visually tracking it, a hoopie-mobile drove past my car making a sound like it had hit it! This distracted me (and my son). I was unable to visually re-acquire the rocket. Having lost a track on it, combined with my brilliant idea to paint it in a camouflage pattern, IT’S LOST. We walked the entire downrange area and after 30 minutes decided to call off the search. So far, it’s not been recovered.

Taser


Our roof top tardy Rocket flies again! This is another one of those really nice fliers. Good aerodynamic balance. This is the rocket that came in our launch kit, and the 1st one we built. Also the one that was lost on the roof of the Gym for a day, eventually taking a short bath in the rain gutter of the school. There is some damage to the lower section of the main body, a little delamination of the tube and somewhat of a soft spot. It’s flying just find though.

The last time we used a larger motor (a B engine) we lost it on top of the school. Since that time I’ve cut 6 1″ slits in the top of the parachute, and most recently opened up a large hole in the center of the chute to further accelerate it’s descent. A good decision.

C6-5 ( 15.3 Newtons thrust) – I had a few of these engines laying around that were given to me (age unknown). Time to use up another motor. Lift off was again straight up. And up, and up! GONE! It went into the low clouds and was GONE. Oh boy. A few seconds later I was able to see it coming down on it’s chute. Yeah! Except it seemed a little too far away, and still drifting downwind. It quickly became clear this was NOT going to land in our LZ. We watched as it drifted above the school and finally out of view over the roof.

Told the boy to pack the gear and hop in the car. If we were lucky it would have completely cleared the entire school and we’d be able to find it. The school is no longer used and most of the grounds are closed off with cyclone fencing making search really difficult. As luck would have it, as I pulled into on of the parking lots on the other side of the school, I noticed something like a pile of trash (amounts all the rest of the trash) right in front of the car that looked odd. Walking over to it, I saw the rocket under the white parachute and completely in tact. YES! Got lucky and got the rocket back! I’m thinking of removing the chute completely and going to a streamer recovery on this one too.

Engine Chart

I finally located an engine chart for the motors that Estes builds. The Estes Rocketry website had nothing but dead links. Luckily their websites is wildly insecure, providing an OPEN INDEX of the their downloads directory.

The direct link to the current engine chart is here:   Estes Engine Chart PDF.    I’ve also downloaded the sheet and am hosting here on my blog, just in case they move it again.  Estes Engine Chart

Conclusions

Wind: Don’t launch in wind, it will just frustrate recovery, and if you have a model with over-sized fins it could mean it that it will run far up-range and possibly make recovery unavailable.

Paint: There is a reason space agencies paint test rockets in orange, they want to be able to see them. The same goes for model rockets. Sure, it’s nice to give them slick paint jobs, nice starburst fades, cool colors and all that. However, if you are unable to keep an eye on the rocket (it’s small, it flyies too high, whatever) painting it in a not-so-cool boring high-vis orange is a BIG plus. Right now I’m repainting the black sections of our Taser in orange for easier location if it goes out of visual range again, as I suspect it will.

New rocket added to fleet

Once I let the oldest launch her first rocket, she was hooked! We spent the rest of the morning burning up about $40 of engines in the rockets. I’d been trying to get her to at least join us to see if she would like to get into model rocketry. Being a ‘girl’ she insisted that she could not because it’s a ‘boy thing’. Happily she disposed of that preconception and was soon anxious to build her own rocket!

After a birthday party event, we headed to the hobby shop to let her pick out whatever rocket she wanted to build. After much deliberation, she selected the ‘Viking Research’ multi-configuration rocket used by the schools (this is probably the same kit I built in Jr. High School!).

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It did not take long to go through the checklist and get the number of fins selected (options ranged from 3 to 5) and which way to mount them on the body tube (there are 4 different ways to mount them, which means you can come up with some interesting designs!).

This is what she decided upon:


A couple of days later, once everything was dried, a few coats of primer were applied and the final color painted we had this gem of a rocket! I look forward to flying it this weekend, and I think she does too!
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A few other rockets are in the boxes, ready to be built. But first a couple of the already constructed models need some work. The most urgent of which is the little Swift 220.

After the first launch, we lost it for a while! It took 30 minutes to find the thing. And the reasons were clear.

  • It was painted a color far too dark, so we lost it in the sky
  • The dark green and yellow paint on the body made it very difficult to spot on the field
  • My little ‘extra’ fins changed the rockets CG to the degree that it was not able to ‘tumble’ back to earth, but instead came down like a dart.

As you might guess, this was hard to find! This is what it looked like when we finally found it!
swift220_2600

After stripping off the extra fins, and sanding to take off the dark paint.. we have this little mess. Lots of work to do on such a little rocket.
Swift220_2614

I have to build one of these!

21cCKCy8p-L._SL500_AA280_The Estes Big Bertha is one of the old-school rockets from my youth. Never built one, but I’m thinking more and more about it with the boy getting into this, and wanting to put large payloads up in the air.

While looking or a decent photo of the thing, I ran across this video of a Big Bertha rocket with video payload. Now.. this is pretty neat. Looking at the lauch areas these people are using, there is no reason we should not be able to pull this off at our ‘secret launch site’.



V2 Camouflage
V2 Camouflage

There is a shorter version of the same rocket, that I’m considering building and painting up like an old WWII V2.

Something to do while it rains.

That gives me 9 months to finish it.