Nose Cone
The nose cone is a custom made design...ok with the help of Rocksim of the Von-Karman power series nose codes. I wanted a good transition though mach up to about mach 3. Also since I made my own tubes to fit my motor cases, the size was a little different for the inside diameter. This required a different size nose cone shoulder. I needed a fiberglass nose code so I needed to make a wood blank to start. With the correct size blank, I will be able to make a fiberglass mould to then make a fiberglass nose cone in the exact shape I make the blank in. So I started buy gluing two pieces of wood together using wood glue and letting them dry overnight. I then Cut the wood down on a table saw and cut the corners off at a 45 degree angle to make the wood more manageable in the lathe. Once It was in the lathe I shaped it to the correct shape and length. I sanded the nose cone down starting with 60 grit, then 100 and then 220. I sanded it smooth all so all I then need to do is paint it to have a smooth surface.
Body Tube
The tubes consist of four wraps of 8.2 oz fiberglass and one medium 2.0 inch Aerosleeve sock. I started of with the four wraps of glass that went over two wraps of 4 mil clear mylar. Once all the fiberglas was wetted out, I carefully put the sock over the wet fiberglass. Once it was in the proper place I gripped the center of the mandrel and using both my hand
s I squeezed the Aerosleeve and move my arms outwards from the center. I kept doing this until the Aerosleeve was completely wet for the fiberglass underneath the Aerosleeve. I set it aside to cure. Once the tubes where dry, I light sanded the tubes using my lathe to just get the rough high spots off. I then used Super Fil to fill in the low spots and set it aside to dry again. Super Fil is a product by Ploy Fiber that is a very light epoxy filler the sands easy. I used a bondo squeegee to apply the Super Fil product. It takes a bit getting used to, but once you do, you can make a little go a long way.
More coming soon.