![]() |
![]() |
![]() |
![]() |
That's how it all started (July 3rd - 2019)
|
The vertical belt around a landing pod
|
Every cut has to be angled
|
More angled pieces
|
![]() |
![]() |
![]() |
![]() |
I REALLY could have used some more hands here...
|
The top of the pod is closing up
|
Top + middle belt of the pod
|
Angles
|
![]() |
![]() |
![]() |
![]() |
Down to the bottom of the case
|
Corner pieces...
|
...for the bottom finish
|
Like that... one basic pod done... three more to go
|
![]() |
![]() |
![]() |
![]() |
Thickness added for the landing foot
|
Even though it's hollow below, it looks as it should
|
Balance
|
Now to the top of the foot
|
![]() |
![]() |
![]() |
![]() |
I do not have access to a cnc machine...
|
...so everything is done by hand
|
Strange patterns... cut with jigsaw
|
to fit this strange thing
|
![]() |
![]() |
![]() |
![]() |
Fits (almost) like a glove
|
Bottom view
|
Mounted on top of the foot...
|
...it begins to look recognizable
|
![]() |
![]() |
![]() |
![]() |
It's a kind of magic
|
On to the next three feet
|
Half done with the underside, and the lights went
out
|
All four feet now soled
|
![]() |
![]() |
![]() |
![]() |
Looks better from above
|
88 'toes' measuered, cut and placed loosely
|
88 toes x 4 = 352 rounded corners... phew
|
Parts for the three remaining pods
|
![]() |
![]() |
![]() |
![]() |
Just like that... a bit refined construction
|
The top finished
|
Cut aways for the lower part sides
|
Fitted
|
![]() |
![]() |
![]() |
![]() |
Now the lower finishing parts... more feet
|
...with supporting sides
|
...done
|
All corner pieces and side panels now glued together
|
![]() |
![]() |
![]() |
![]() |
Details cut for the vertical sides. Placed with template
|
MAX pressure for max glue effect
|
Three on line
|
More pressure delivered by Max
|
![]() |
![]() |
![]() |
![]() |
Start of decoration. The pod details. One side...
|
...the other two sides. Top sides next...
|
Trapez
|
Trapez x 16
|
![]() |
![]() |
![]() |
![]() |
I did not have wood that thick...
|
...so glue and screw...
|
...made nice blocks
|
Nose...!?!
|
![]() |
![]() |
![]() |
![]() |
4 noses
|
Details cut with jigsaw for the top part.
|
Glued on... left wing...
|
...and right wing
|
![]() |
![]() |
![]() |
![]() |
Now to these little fellas... the Gemini parts
|
I had six half spheres hand made (not by myself)
|
Maybe slightly too big, but I think it is okay.
|
Daniel Prud'Homme helped me with the details
|
![]() |
![]() |
![]() |
![]() |
Good old technical drawing
|
Calculating and measuring...
|
Template... made... for the 12 holes for the bolts.
|
One more template for the off-center placement.
|
![]() |
![]() |
![]() |
![]() |
The six half spheres got marked...
|
...and on with the band grinder.
|
6 discs measured and cut.
|
One ready to mount.
|
![]() |
![]() |
![]() |
![]() |
...and 5 more
|
72 holes drilled and 72 bolts mounted
|
Large center hole drilled.
|
Not the correct tube yet... but we're getting there.
|
![]() |
![]() |
![]() |
![]() |
Stainless steel tube for the centre
|
Inserted
|
Now for the Saturn V part
|
It took some thinking... to think the design out
|
![]() |
![]() |
![]() |
![]() |
Small cylinders cut from a stick
|
for another nose
|
Noses with holes
|
Rough wings
|
![]() |
![]() |
![]() |
![]() |
A model was created
|
gonna watch my fingertips
|
All survived
|
Then a little grinding with the grinding mouse
|
![]() |
![]() |
![]() |
![]() |
16 small wings
|
Now make some place for them
|
Handmade... takes time
|
But the time goes by - as time does
|
![]() |
![]() |
![]() |
![]() |
These holes wasn't as easy as I thought
|
Because the bolts had square shape beneath the head
|
And the thread wasn't cut all the way up either
|
But finally...!
|
![]() |
![]() |
![]() |
![]() |
Looks as it should - I think
|
A status parade
|
All cracks, screwholes and sides...
|
...padded up (one pod only... for now)
|
![]() |
![]() |
![]() |
![]() |
A3 prints taped together for the Command Module.
|
Measuring en masse...
|
Cutting...
|
Fitting...
|
![]() |
![]() |
![]() |
![]() |
The back side of the CM
|
Horizontal ribs added...
|
...and vertical ribs added
|
Direct back view
|
![]() |
![]() |
![]() |
![]() |
Two more vertical...
|
The puzzle pieces taken apart to double up...
|
...for the 'downunder' part
|
Status March 13th - 2020
|
![]() |
![]() |
![]() |
![]() |
2 x back side ribs finished
|
Cutout for the top (or bottom) alu 'disc'
|
Support for the alu 'disc'
|
Both top and bottom 'disc-housing' done
|
![]() |
![]() |
![]() |
![]() |
One side disc (housing) done...
|
...other side disc (housing) done
|
all panels are now glued together - and edges sanded...
|
...sanded to make a smooth surface for... sticks!
|
![]() |
![]() |
![]() |
![]() |
I have tried to copy these as close as possible
|
The boosters on the 44" studio Eagle 1 are angled
|
78 degrees.... circa
|
A thin wooden disc, very fragile to cut, do the trick
|
![]() |
![]() |
![]() |
![]() |
It do matter how the discs are placed.
|
90 degrees flat on the block... or on the bell...
like this
|
These really looks nice on the pod
|
deserves a closer look
|
![]() |
![]() |
![]() |
![]() |
Back to the sticks... lots of sticks... looking rough...
|
...until sanded down. No sticks are the same shape.
|
Top view... middle section of sticks sanded down.
|
One flank of sticks glued on... not yet sanded.
|
![]() |
![]() |
![]() |
![]() |
Opposite side flank... not yet sanded.
|
A front row of sticks added.
|
And now to the back side of the Command Module.
|
Two columns.
|
![]() |
![]() |
![]() |
![]() |
Right flank sanded
|
Three columns.
|
Corner part and sanding.
|
Necessary weight reduction.... for my back!
|
![]() |
![]() |
![]() |
![]() |
More sticks... to the right...
|
...to the left
|
Left corner...
|
...closing up.
|
![]() |
![]() |
![]() |
![]() |
Left and right back side sanded smooth.
|
The middle section panel also weight lightened.
|
Placed... and glued on.
|
Pressure to secure tight fit.
|
![]() |
![]() |
![]() |
![]() |
Side ribs in place and glued on. Additional nose panels.
|
Nose tip sticks... rough...
|
...and sanded down.
|
Right side... under window section sticks.
|
![]() |
![]() |
![]() |
![]() |
Right side sticks completed.
|
Crack at window...
|
...every stick shaped independently.
|
Smooth fit.
|
![]() |
![]() |
![]() |
![]() |
Right side sticks sanded.
|
Left side sticks before sanding.
|
Suddenly some 'bling-bling' arrived for the CM.
|
They really decorates beautifully!
|
![]() |
![]() |
![]() |
![]() |
Top side done for now.
|
More weight reduction.
|
Opposite side panels in place.
|
Nose tip panels... ready for sticks.
|
![]() |
![]() |
![]() |
![]() |
Small special shaped sticks.
|
2 x 57 = 114 sticks used for the nose tip.
|
Left and right flank of oblong sticks.
|
The horizontal belt are too thick. Gotta adjust, but
how?
|
![]() |
![]() |
![]() |
![]() |
Some heavy sanding helped... but was it enough!?
|
A little colour added (in Photoshop).
|
Batten supports for the removable downside triangles.
|
Lots of holes drilled for weight reduce.
|
![]() |
![]() |
|
![]() |
Also at the back.
|
Ready for sticks adding...
|
Going.
|
All different shapes.
|
![]() |
![]() |
![]() |
![]() |
Extra supports added for the round 'thingy'.
|
And more special shaped sticks.
|
It fits nicely.
|
It's a puzzle.
|
![]() |
![]() |
![]() |
![]() |
Maybe a bit boring (for some) with all those sticks.
|
But progres shows.... slowly.
|
Both flanks now 'sticked'... but I see something is
missing.
|
Weight reduce holes... drilled.
|
![]() |
![]() |
![]() |
![]() |
Left back side getting sticked.
|
And right back side.
|
The upper and lower halves put together...
|
...for a show beside a 22" model.
|
![]() |
![]() |
![]() |
![]() |
Back side edges grinded smooth... left...
|
...and right.
|
Fail hollows in the wood appears later when sanding.
|
Status december 13th 2020.
|
![]() |
![]() |
![]() |
![]() |
Additional template for the corner.
|
Finished corner panel (other side).
|
Sticking the corner... left column.
|
Sticking the corner... right column.
|
![]() |
![]() |
![]() |
![]() |
Both corners now closed up, leaves the difficult gap.
|
An additional half ring made for separation purpose..
|
Building up sticks around the 'disc holder'.
|
First column.
|
![]() |
![]() |
![]() |
![]() |
Second column closed up. The third will have to wait.
|
Back view all cornered up.
|
The opposite side also closed up around the ring.
|
The special wooden block is cut into two for a reason.
|
![]() |
![]() |
![]() |
![]() |
This is where the two halves are going to separate.
|
Back view all sanded smooth.
|
Final gap closing up. Top sticks needs special attention.
|
Customization by hand (and band grinder) as usual.
|
![]() |
![]() |
![]() |
![]() |
Very slowly grinding progress makes perfect fit.
|
Finally! ...eh for one side.
|
Looking more and more complete.
|
See you in the mirror.
|
![]() |
![]() |
![]() |
![]() |
All sanded nice and smooth.
|
Now for the other side... the final gap.
|
Both sides now completely closed up.
|
And luckily the two halves still did separate!
|
![]() |
![]() |
![]() |
![]() |
An extra ring sawed and glued on to reach level.
|
Other side.
|
Also for the top and bottom.
|
And then... sanding...
|
![]() |
![]() |
![]() |
![]() |
And dirting...
|
...until I ran out of sanding paper.
|
Had to order new supplies.
|
And then on to finish.
|
![]() |
![]() |
![]() |
![]() |
Unforseen bad luck struck...
|
A hole appeared in my experimental structure.
|
Additional wood stick and filler.
|
Ready for the next chapter.
|
![]() |
![]() |
![]() |
![]() |
Now for the exalted details. I changed my mind...
...and decided to cut down instead of add more weight. |
I thought this was straight forward measuring... but
no.
|
These lines shall be straight to look at... but weren't.
|
A new method needed.
My old Flexicurve from school came in handy. |
![]() |
![]() |
![]() |
![]() |
And helped me make a template.
|
Now the lines has to be straight!
|
I had to adjust the template for each line.
|
Because of the rounding change along the 'nose back.'
|
![]() |
![]() |
![]() |
![]() |
I present a new toy... a router... this should be
fun
|
This maybe look easy, but believe me...
|
...handling the router in free hand made me sweat!!
|
Now to some lines on the rest of the module.
|
![]() |
![]() |
![]() |
![]() |
Quite a lot of measuring. Checking photos and drawings.
|
Here I have sharpened the pencil up in Photoshop.
|
Close up pencil lines.
|
This is what I love and are my actual education.
|
![]() |
![]() |
![]() |
![]() |
But nevertheless... LOTS of rubber shavings on the
floor.
|
Pencil lines on the back of the module.
|
Photoshop.
|
Double checking drawings and photos from the web.
|
![]() |
![]() |
![]() |
![]() |
Both side drawn.
|
Top and bottom ready for the router.
|
More surprise hollows appeared on my way.
|
Again... lining up the side were a pain to get correct.
|
![]() |
![]() |
![]() |
![]() |
It was quite frustrating.
|
Afterwards I came to think of a laser liner.
|
That would have been real handy.
|
But after lots of rubbering they finally looked right.
|
![]() |
![]() |
![]() |
![]() |
Complete lines - front.
|
Complete lines - back.
|
Now on with the router. Concentration.
|
Softening with the grinding mouse.
|
![]() |
![]() |
![]() |
![]() |
And correcting with the file.
|
Here's why all the sticks had to be trapez shaped.
|
Here's my second work with the router
|
Better lighting. Looks quite okay I think.
|
![]() |
![]() |
![]() |
![]() |
And the back side left and right.
|
I should have timestamped the photos.
|
Here it is clear how easily the router went off track.
|
And here... which needed following attention.
|
![]() |
![]() |
![]() |
![]() |
But it is just a matter of time.
|
At last...!
|
Oh.... I forgot... there's another half side.
|
With those 'exciting' sides.
|
![]() |
![]() |
![]() |
![]() |
I did a lot of 'hold my breath' while routing.
|
But it paid off.
|
Closeup...
|
...details.
|
![]() |
![]() |
![]() |
![]() |
Now it really look right.
|
I'll let the photos...
|
...speak for themselves.
|
Next thing coming up....
|
![]() |
![]() |
![]() |
![]() |
A bit wood work still needed before the tubes.
|
Two frames completed to keep tubes fixated.
|
Alternative tower drilling machine.
|
And then cup drill.
|
![]() |
![]() |
![]() |
![]() |
Those corks got stuck inside each and single time.
|
Finally. After intense measuring and drilling.
|
A little oldfashioned finish.
|
The wooden parts ready.
|
![]() |
![]() |
![]() |
![]() |
16 special tabs made to support the tubes.
|
Finally unpacking. I need 8 x 540mm straight cut.
|
Fitting the Ø40mm tubes.
|
Then kept fixed between the two frames.
|
![]() |
![]() |
![]() |
![]() |
Milling cutting...
|
...makes those 'fish mouths'...
|
...for perfect fit.
|
Status March 21st 2021.
|
![]() |
![]() |
![]() |
![]() |
Obligue tubes mounted temporarely.
|
And the short side tubes. The thinner horizontal.
|
More fish mouths...
|
...so those obligue tubes can be pushed in place.
|
![]() |
![]() |
![]() |
![]() |
Four tubes meets
|
Five tubes!
|
The first diagonal...
|
...and the first cross done!!
|
![]() |
![]() |
![]() |
![]() |
Some time went by before I was able to weld...
|
...early in progress I decided to weld inside of the
cage only. It looked too ugly no matter how nice a weld I made.
|
Apart from the two small tube to finish the X...
first cage now done. |
And without it's supporting taps.
|
![]() |
![]() |
![]() |
![]() |
Eight new special taps with a diving collar was made.
|
To build the next cage on top of the first.
|
To have them perfectly match up.
|
And freed from supporting frame.
|
![]() |
![]() |
![]() |
![]() |
Suddenly three cages were done...
|
...and ready for the fourth.
|
Me in action.
|
Al the tubes became very HOT while welding.
|
![]() |
![]() |
![]() |
![]() |
Two pair of cages.
|
And now to the last two pieces to complete the X.
|
With this I got CNC help from my brother in law.
|
These were tricky... but after some time, they did
fit.
|
![]() |
![]() |
![]() |
![]() |
Here's an illusion photo... before the X was actual
made.
|
Primitve, but effective tool I made to keep the pieces
fixed.
|
Top (one side) X's done.
|
And the other side. Four cages completed.
|
![]() |
![]() |
![]() |
![]() |
Laid down and pulled apart.
|
But back together again to spare floor room.
|
But it looks nice.
|
Tunnel view....
|
![]() |
![]() |
![]() |
![]() |
Now to the rear enginge section.
|
I needed more hands...
|
...but large clamps helped me.
|
Now what....
|
![]() |
![]() |
![]() |
![]() |
Eight longitudinal tubes added. I lacked hands again.
|
And again, but Kurt gave a helping hand holding tubes.
|
Rear section done - except for the four rings...
|
...for the engine bells.
|
![]() |
![]() |
![]() |
![]() |
Now on to the...... spine!!! And the Ø 50mm
tubes.
|
I cut the longest tubes for the spine (Ø 40mm).
|
And couldn't help myself dragging it all outside.
|
Into the bright evening daylight, casting long shadows.
|
![]() |
![]() |
![]() |
![]() |
First cut... in both ends Ø 40mm.
|
Second... milling for the 47 degree angels.
|
Dejavue.
|
Loosely setup - all Ø 40mm
|
![]() |
![]() |
![]() |
![]() |
Herd of Minions - Ø 50mm.
|
Ø 50mm packed in box
|
Ø 50mm wrapped around three meeting Ø
40mm.
|
Left 133 degree - right 47 degree.
|
![]() |
![]() |
![]() |
![]() |
Inside look.
|
133 degree.
|
47 degree.
|
Assembled.
|
![]() |
![]() |
![]() |
![]() |
Now for the longitude tubes.
|
Can't explain HOW difficult these two tubes
were to slide into the middle. So extreme tolerance. |
The shorter ones were a lot easier.
|
And suddenly... all four long tubes were fitted with
the thicker joint tubes.
|
![]() |
![]() |
![]() |
![]() |
Close up... one
|
...two...
|
three... and four.
|
Then the transverse tubes.
|
![]() |
![]() |
![]() |
![]() |
Building up the 'second floor' made me wanting to
be an octopussy. Tubes scrambled to the floor...
|
...but again... after a long battle, it was all in
place.
|
Strips around to avoid it to fall apart. And a heavy
duty dozer bar to force everything together while welding.
|
The very first spot weld to the spine.
|
![]() |
![]() |
![]() |
![]() |
Here's a tunnel view.
|
Bottom up.. the downside of the spine.
|
Welded joint (left) and non welded joint (right).
|
First diagonal tube in place... the rest followed.
|
![]() |
![]() |
![]() |
![]() |
First corner tube in place, but I forgot the transverse
tube.
|
So a special cut (for the first two) were made manually
to fit the transverse tube. |
As shown here.
|
Two corner tubes in place.
|
![]() |
![]() |
![]() |
![]() |
Almost done...
|
...only the last two corner tubes missing
along with the last tranverse tube. |
Old fashioned marking... with a marker.
|
This is not calculating.
|
![]() |
![]() |
![]() |
![]() |
I cross my fingers that it will work.
|
Then into the milling machine.
|
Kind of art.
|
A bit of luck made it a perfect fit.
|
![]() |
![]() |
![]() |
![]() |
Two tubes milled and ready to fit...
|
...along with the transverse tube.
|
Spine is now ready to weld...
but only on the down- and inside |
End view.
|
![]() |
![]() |
![]() |
![]() |
The spine got turned upside down again...
|
...to access the joints that shall be welded.
|
And here we go...
|
It is strong, but it will look too ugly on the visible
outside.
|
![]() |
![]() |
![]() |
![]() |
These four rings I did not make myself,
but I did get the tube endings grinded to fit them. |
And I did also weld them onto the rear section.
|
Time for an assemble.
|
No... there's not two... just from the other side.
|
![]() |
![]() |
![]() |
![]() |
Now on to the 16 brackets
that shall hold the spine firm to the cages. |
Plates... some milling and drilling... and last bending.
|
The original filming model had 'L' shaped brackets.
But at this size I feel more confident with the 'U' shape. |
All 16 brackets welded onto the four cages.
|
![]() |
![]() |
![]() |
![]() |
But that bolt's head doesn't look right.
|
Special discs were made, and welded onto the head.
|
And painted red... or... yes it is lava hot!!!
|
Almost perfect! The bracket should have been a little
longer or a bit more narrow, but I wont redo it.
|
![]() |
![]() |
![]() |
![]() |
My first drwing of the six flanges for the front frame.
|
CNC milled. Two pieces from a block of aluminium.
|
Cut in...
|
...two.
|
![]() |
![]() |
![]() |
![]() |
And then Milled again on both sides.
|
My paint plan, to make it look as on the original
44" Eagle.
|
Front frame can now be build up.
|
Now only missing the four tubes for the flanges.
|
![]() |
![]() |
![]() |
![]() |
Top (or bottom) flange pair sled on.
|
Front frame complete with all flanges.
|
The space needed between front frame and cage...
|
...are created by extending these short tubes.
|
![]() |
![]() |
![]() |
![]() |
Now the cages guiding taps. First some heat...
|
...then it taps firmly in.
|
Upper taps longer than lower taps.
|
The front frame fitted with taps also.
|
![]() |
![]() |
![]() |
![]() |
And the rear engine cage section also.
|
Now for the bearing construstion in the cages.
|
Guide boxes are made of aluminum plates...
|
...welded together to form a box.
|
![]() |
![]() |
![]() |
![]() |
Ready to go...
|
First some spots.
|
I ran out of argon, shown by the black spots.
|
But after a refill, it could be all cleaned up.
|
![]() |
![]() |
![]() |
![]() |
All four boxes ready.
|
Sled onto the bearing bar and laid on the cage...
|
...marked up - and then a strange feeling while cutting
in the beautiful cages. But it had to be done. |
Gap a bit too small.
|
![]() |
![]() |
![]() |
![]() |
Adjusted with a file... but that took too long.
|
So I got help from an angle grinder.
|
The boxes in place in cage.
|
A dozer bar helps keeping the tubes in place.
|
![]() |
![]() |
![]() |
![]() |
Ready to see if the bar fit.
|
It did - and after some small adjustment...
|
...there were enough free space around.
|
Tunnel view.
|
![]() |
![]() |
![]() |
![]() |
The boxes welded in place.
|
Cleaned up.
|
Until a test it looks like the idea will work.
|
This bearing construction differs from the original
Eagle.
|
![]() |
![]() |
![]() |
![]() |
The black steel bars were exchanged for stainless
ones.
|
Also stainless steel for the legs. Cutting tube.
|
Four legs and four tubes to be integrated with the
bars.
|
The two transverse bars.
|
![]() |
![]() |
![]() |
![]() |
An angled cut to fit inside the shoulder pods.
|
Package so far. Back to the wooden parts.
|
Finding the center of the foot..
|
Hole drilled through.
|
![]() |
![]() |
![]() |
![]() |
To locate center from beneath.
|
Then drilled larger...
|
...through two layers of plywood.
|
And the hole for the stainless leg are done.
|
![]() |
![]() |
![]() |
![]() |
The shoulder pods also need some drilling.
|
Four corner holes.
|
And then the jigsaw.
|
And last some filing.
|
![]() |
![]() |
![]() |
![]() |
Ready for the inside bar-rest-guide.
|
45 degree ends.
|
checking...
|
Cut-outs.
|
![]() |
![]() |
![]() |
![]() |
Glue.
|
Pressure.
|
Four guide-shoes ready to be inserted.
|
A little step up, make room for...
|
![]() |
![]() |
![]() |
![]() |
...a layer of smooth click-floor that I had already.
|
Outer end (the four bolts are the Saturn V part).
|
And then checking with a leftover bit of bar.
|
Fits nice on the inside too.
|
![]() |
![]() |
![]() |
![]() |
Back in the machinery, holes were drilled.
These are for attachment inside the shoulder pod. |
A special tap welded in one end of the legs.
|
To fit into the bushing welded into the transverse
bar.
|
The stainless steel bearing parts assembled.
|
![]() |
![]() |
![]() |
![]() |
Four 'bearing' feet laser cut. Weighing 35kg each.
|
A rod welded tight to greet the open end of the leg.
|
And then having the wooden foot slided down over.
|
140kg feet on a Euro pallet.
|
![]() |
![]() |
![]() |
![]() |
First try on raising half of the construction.
|
Once tipped up and it stood solid.
Mission completed... for now. |
Meanwhile I cut four short aluminium tubes for the
flanges that shall connect with the Command Module brackets. Top/bottom
shown above...
|
...and above here are shown the side flange with tube.
|
![]() |
![]() |
![]() |
![]() |
First try on raising the complete tube construction.
Spine laying ready on the fork lift. |
First the cages are assembled laying down.
|
The heavy feet mounted. The cages tip by the weight.
|
Then the cages easily raised up into position.
|
![]() |
![]() |
![]() |
![]() |
The spine is a two man job only. Weiging 70-80kg.
|
It was gripped nice by the U-shaped brackets.
|
Holes were drilled into the spine...
|
...and the special made bolts inserted and tightened.
|
![]() |
For scale comparison I added... ...me!
The structure still short of engine bells and command module, which is about 2 extra meters. Speaking of... check below... |
![]() |
![]() |
![]() |
![]() |
A large package I've had for awhile now... time to
open!
|
Content: 4 large plant pots... say what!?!?
|
Look at those trumpet endings... no no no.
|
And sweet flowers and butterflies.
|
![]() |
![]() |
![]() |
![]() |
Forward with the anglegrinder.
|
Grinder fixated to the working table.
|
Set height.
|
Off goes the trumpet edge.
|
![]() |
![]() |
![]() |
![]() |
Now that's better!
|
But I need to make an adapter form to connect the
engine bells to the rear engine section frame. |
It's not 100% acurate, but I think this will do.
|
Paint test... Edding silver spray... to pass as aluminum.
|
![]() |
![]() |
![]() |
![]() |
Geting ready for the Command Module brackets.
|
Measuering and lining up...
|
Had to file a bit in the CM to make the front frame
fit.
|
Perfect fit left / right.
|
![]() |
![]() |
![]() |
![]() |
My paint plan to make these solid flanges look as
on
the filming model. |
A small brick...
|
To even out the distance at bottom...
|
...and top.
|
![]() |
![]() |
![]() |
![]() |
Perfect fit top / bottom.
|
front view.
|
Back view.
|
Cardboard template for side bracket.
|
![]() |
![]() |
![]() |
![]() |
Then another template of wood is made.
|
Cardboard template for top bracket.
|
The wooden templates seems to fit well.
|
Both wooden templates ready to be made in aluminum.
|
![]() |
![]() |
![]() |
![]() |
Small spots of rust have appeared on the feet.
|
So on with some Nutella - and then som Hammerite.
|
Four feet painted on top...
|
...and four feet painted beneath.
|
![]() |
![]() |
![]() |
![]() |
More discs made for the remaining three thrusters.
First four cuts to make an rectangle, then four 45 degree cuts to make an octagon, then last eight 22.5 degree cuts. |
The rest of the edges are grinded down
to make a circular disc. |
The smaller ones screwed together as pairs
to make thicker discs. |
And the larger ones connects to the thruster.
All four now done. However the even smaller ones for the inside of the aluminum rings are yet to be made. |
![]() |
![]() |
![]() |
![]() |
Four blocks sawed from an old wooden table.
|
Served on the four rings.
|
'Rotation' marked for later use.
|
Also ring marked beneath.
|
![]() |
![]() |
![]() |
![]() |
Same procedure as the other end parts.
|
Sawed slowly in to the circle mark.
|
That's as close that I get with the table saw.
|
Just a little too big now. The rest will the band
grinder do.
|
![]() |
![]() |
![]() |
![]() |
There! It sinks nicely down into the ring.
Because the rings aren't 100% circular, the wooden disc will lock tight into the ring when turned. That's exactly the idea. |
Now all the discs can be screwed together,
on top of eachother. |
One engine bell (stacked on top of the other three).
|
All four engine bells now ready to be inserted
into their each own dedicated ring on the rear frame. |
![]() |
![]() |
![]() |
![]() |
Next big step.... the Passenger Pod.
Lines measured and drawn |
Sawed and copyed to next board.
|
A mess on the floor.
|
Both gables sawed... and floor cleaned up.
|
![]() |
![]() |
![]() |
![]() |
Tiny tracks cut on the table saw.
|
Four sectiones with tracks.
|
Not bad.
|
They fit here.
|
![]() |
![]() |
![]() |
![]() |
Surrounding board lined up.
|
And cut.
|
Track section screwed onto the back.
|
The result.
|
![]() |
![]() |
![]() |
![]() |
Looks good.
|
Even though the gables are not vivible when the pod
is mounted to the Eagle, I have to do the details.
No cheating here. |
This is actually wrong line up, but was corrected
before cutting. |
Technical lines.
|
![]() |
|
|
|
Here's the lines corrected.
|
Ready to drill the corners.
|
And the longsides is cut with the jigsaw.
|
Voila.
|
|
|
![]() |
![]() |
Voila x 2.
|
Placed in place.
|
The rest of the details are cut out from a cheaper
board.
|
Completed.
|
![]() |
![]() |
![]() |
![]() |
Next... the window sections.
|
Again... measuring... line drawing.
|
Pre-drilling the corners.
|
First corner.
|
![]() |
![]() |
![]() |
![]() |
And a lot of corners and longsides after.
|
The thinner window separation section.
|
Lots of cornes drilled with a spade drill.
|
And the jigsaw did the rest.
|
![]() |
![]() |
![]() |
![]() |
One window section...
|
...fitted to one gable and one side.
|
Then there's a lot of repeating work to be done.
|
But as times goes by... finally all four done.
|
![]() |
![]() |
![]() |
![]() |
Next - the middle section...
|
....of the sides.
|
Side door detail 1.
|
Side door detail 2.
|
![]() |
![]() |
![]() |
![]() |
fitted between two side sections.
|
Additional boards above the door.
|
All assembled.
|
Closer look at the door section.
|
![]() |
![]() |
![]() |
![]() |
Everyhting taken apart.
|
Now time to gables fit the cages.
I draw two circles. |
And drill holes.
|
A loadbearing batten is mounted.
|
![]() |
![]() |
![]() |
![]() |
And some deaper drilling.
|
Kurt made these bearing taps.
|
Two pieces for each gable.
|
Complete.
|
![]() |
![]() |
![]() |
![]() |
The I had to assemble the cages with the spine.
To get the exact meaure between the gables. |
Inbetween I made the backboard
for the details on the gables. |
A track cut to support the back board at the bottom.
|
Like this.
|
![]() |
![]() |
![]() |
![]() |
The rest of the back board are screwed on.
And later glue will be added. |
Details placed.
|
Next. The lenght of the pod.
Battens cut. |
Two small battens for the top of the gables.
|
![]() |
![]() |
![]() |
![]() |
A change of my design. I thought it would be better
having the roof board reaching over the gables. |
The short supporting battens.
|
Sawed multiple times made a wide track.
|
And the same method to the ends of the long battens.
|
![]() |
![]() |
![]() |
![]() |
The short battens screwed onto the gables.
|
Ready to greet the long battens.
|
Like this. Looks simply,
but it took som adjusting before I was satisfied. |
There's the length of the passenger pod.
2 meter and 70 centimeter. |
![]() |
![]() |
![]() |
![]() |
On to the roof. Will be in three sections.
|
an oblique cut on the full length sides.
|
But an even smaller angle are needed.
|
Which is done with the band grinder.
|
![]() |
![]() |
![]() |
![]() |
First board done.
|
Angle comparison.
|
Roof on top.
|
Test fitting of a window section. It fits.
|
![]() |
![]() |
![]() |
![]() |
Now onto the gutter battens. Made of one heavy pole.
|
Fuses blew. I had to cut from both sides of the pole.
|
And finally - cast irons to split it apart.
|
Work only half done. They need to be cut through again.
|
![]() |
![]() |
![]() |
![]() |
Now we're getting there.
|
Laid on the windows section.
|
A premade template.
|
Curved line drawn in pencil.
|
![]() |
![]() |
![]() |
![]() |
Back to the table saw.
|
And then band grinder to make it all smooth rounded.
|
Screwed onto the windows section... more grinding.
|
Until the section completes the round shape.
|
![]() |
![]() |
![]() |
![]() |
Looks good - part I
|
Looks good - part II
|
Second batten
|
Moved outside, but same procedure
|
![]() |
![]() |
![]() |
![]() |
Grinding outside makes less mess inside.
|
Both windows sections completed.
|
Next: The Gemini #29 (and #28) part.
|
Small boards cut into shape.
|
![]() |
![]() |
![]() |
![]() |
Sloped tip sawed.
|
Fine grinding
|
Couldn't find correct diameter round sticks...
|
...so I bought this wooden tile instead.
|
![]() |
![]() |
![]() |
![]() |
Only to use the wooden bricks on it.
|
I round grinded the longitude edges.
|
Inbetween I made the #28 Gemini bricks.
|
Line up with the side rounded bricks.
|
![]() |
![]() |
![]() |
![]() |
I cut off all the rounded sides...
|
...I only need the round part of the bricks.
|
Then the small rounded sticks are cut into shorter
ones.
|
All the ends needed to be rounded too.
|
![]() |
![]() |
![]() |
![]() |
A considerable time after... (even the sun had set).
|
But all put together it was worth the work.
|
Parts in place.
|
Now to the sloped boards...
|
![]() |
![]() |
![]() |
![]() |
...at the bottom of the sides.
|
My table saw complained.
|
Burned wood.
|
But I succeeded.
|
![]() |
![]() |
![]() |
![]() |
A lot of tiles cut for the two sloped window sections.
|
But first som padding here and there.
|
||
![]() |
![]() |
![]() |
![]() |
This is only a test glue for one of the tiles.
|
The rst are laying loose until further notice.
|
||
![]() |
![]() |
![]() |
![]() |
Back to the sloped lower panels.
|
The wood have bend itself.
|
So... lots of glue...
|
|
![]() |
![]() |
![]() |
![]() |
And clamps.
|
Revised clamping.
|
two...
|
three...
|
![]() |
![]() |
![]() |
![]() |
And all four done.
|
Now further down below.
|
Angle measuring.
|
|
![]() |
![]() |
![]() |
![]() |
A long batten.
|
Sawed into two. My ridiculous jigsaw.
|
Template making.
|
The template brick.
|
![]() |
![]() |
![]() |
![]() |
Sawing a joint cut.
|
To make it fit...
|
...against the gable batten.
|
And some oblique cutting on the table saw.
|
![]() |
![]() |
![]() |
![]() |
To spare on the band sander.
|
Nice and smooth.
|
Times two.
|
|
![]() |
![]() |
![]() |
![]() |
Mounted.
|
Marking the sides.
|
||
![]() |
![]() |
![]() |
![]() |
Dissasembling the sides.
|
To be able to cut.
|
||
![]() |
![]() |
![]() |
![]() |
Back on - ready for grinding.
|
Almost forgot this short middle piece.
|
Sanding in open air.
|
Marking.
|
![]() |
![]() |
![]() |
![]() |
And then a test assemble of the whole passenger pod.
|
|||
![]() |
![]() |
![]() |
![]() |
I had to redo these two Gemini parts due to wrong
measuring.
|
Now on to a whole other area.
The landing gear. |
Cutting sticks.
|
|
![]() |
![]() |
![]() |
![]() |
And tubes.
|
Cheating 'calculating' angle and length.
|
Bending and squeezing.
|
Here're the sticks being cut.
|
![]() |
![]() |
![]() |
![]() |
The opening in both ends are milled.
|
Sticks done.
|
Here are the tubes being cut.
|
|
![]() |
![]() |
![]() |
![]() |
Tubes squeezed and bend in a 'special' angle.
|
Curtleri ready.
|
Comparing with a photo of the original 44" Eagle
1.
|
Now parts for the elbow joints.
|
![]() |
![]() |
![]() |
![]() |
Square tubes.
|
and rods a being sawed.
|
removing the sharp edges.
|
|
![]() |
![]() |
![]() |
![]() |
My work table.
|
Marking for drilling holes.
|
||
![]() |
![]() |
![]() |
![]() |
Almost forgot these short rods.
|
Holes done.
|
lining up.
|
Marking for rounded ends.
|
![]() |
![]() |
![]() |
![]() |
The band grinder in action.
|
The rods done.
|
Now to the square tubes.
|
|
![]() |
![]() |
![]() |
![]() |
These are a little more tricky.
|
This area will be cut open to allow the arm to bend
more.
|
||
![]() |
![]() |
![]() |
![]() |
Moving on to another area of the landing gear.
|
Milling small flat areas on two sides of the flanges.
|
||
![]() |
![]() |
![]() |
![]() |
And also the short rods needs milling.
|
And further modelling.
|
To fit onto the ring flange.
|
|
![]() |
![]() |
![]() |
![]() |
Ready for welding the long sticks onto the flange.
|
And then the short rods.
|
Aslo welded on.
|
|
![]() |
![]() |
![]() |
![]() |
All four done.
|
And a quick loose assemble. Looking good.
|
Two top plates
|
|
![]() |
![]() |
![]() |
![]() |
A distance piece of tube inserted temporary.
|
|||
![]() |
![]() |
![]() |
![]() |
Kurt is doing the welding.
|
|||
![]() |
![]() |
![]() |
![]() |
All welded.
|
And then another loose assembling.
|
||
![]() |
![]() |
![]() |
![]() |
To enjoy the sight.
|
The gear is held up alone by this area.
|
||
![]() |
![]() |
![]() |
![]() |
Back home from Kurt with all the landing gears.
|
|||
![]() |
![]() |
![]() |
![]() |
Now back to the brackets for the Command Module.
|
The wooden templates need to be made in aluminium.
|
||
![]() |
![]() |
![]() |
![]() |
Cutting pieces from a solid block and then into shape.
|
Rough shape for a start.
|
Basic shape.
|
|
![]() |
![]() |
![]() |
![]() |
Ready for welding.
|
Tracks are made for deeper welding.
|
First spots...
|
|
![]() |
![]() |
![]() |
![]() |
Aluminium gerts very hot when welded.
|
Done deep.
|
Some attention is needed.
|
There's not enough room...
|
![]() |
![]() |
![]() |
![]() |
For the hinge flanges.
|
Solving this by milling two tracks in the bracket.
|
Drilling holes and marking up for rounding the ends.
|
Some time later.
|
![]() |
![]() |
![]() |
![]() |
Now it fits.
|
Also on the front frame.
|
Four brackets for the CM.
|
Cutting some black vinyl.
|
![]() |
![]() |
![]() |
![]() |
Turning.
|
Drilling.
|
And nice bushes for the brackets.
|
Fits!
|
![]() |
![]() |
![]() |
![]() |
The front frame.
|
And the brackets.
|
Oops....
|
...two earlier photos.
|
![]() |
![]() |
![]() |
![]() |
The vinyl bushing in place.
|
Looks professional right?!!
|
Complete front frame with hinges
|
A closer look at the two tracks milled to give room.
|
![]() |
![]() |
![]() |
![]() |
A test fit to the CM on our terrace.
|
Preparing transporting the CM.
|
First half.
|
and the second.
|
![]() |
![]() |
![]() |
![]() |
Cool.
|
IF it's gonna rain... better secure.
|
Arrived at Kurt's metal business.
|
Drilling holes in the brackets.
|
![]() |
![]() |
![]() |
![]() |
Marking on the CM where the bolt will go in.
|
Making room for it.
|
||
![]() |
![]() |
![]() |
![]() |
Placing the nut.
|
A long flat bracket
|
Bend aroung the nut in the plywood.
|
This mounting look piece of cake... but it wasn't.
|
![]() |
![]() |
![]() |
![]() |
I hope it works.
|
Preparing.
|
Test fitting one bracket.
|
The lower bolt.
|
![]() |
![]() |
![]() |
![]() |
Here's why it wasn't a walk in the park.
Because of lack of room, I had to manual drill holes with my hands. |
But as many times before... time went by.
|
Sawdust.
|
Now the front frame fitted to the CM by the
top and bottom hinges. |
![]() |
![]() |
![]() |
![]() |
The side hinges will have to wait.
|
But it look like it will fit promissing.
|
||
![]() |
![]() |
![]() |
![]() |
Now after a year of waiting, the CM finally is been
closed up to the back.
|
First stick made to fit... I now the drill....
|
Working area on the terrace.
|
Five sticks glued in place.
|
![]() |
![]() |
![]() |
![]() |
Down to the bracket.
|
And further down...
|
To gain access from the inside, I use the bajonet
saw.
|
|
![]() |
![]() |
![]() |
![]() |
There.
|
If I need future access after closing the CM all up.
|
The day comes to an end.
|
|
![]() |
![]() |
![]() |
![]() |
Continuing next day
|
Now.
|
All the way down...
|
...and I can start all over on the second half part.
|
![]() |
![]() |
![]() |
![]() |
Same procedure.
|
Also making room with the bajonet saw.
|
Sticks reaches down to the bracket.
|
|
![]() |
![]() |
![]() |
![]() |
And further down
|
Bracket surrounded by sticks.
|
||
|
|
|
|
Test fitting of bracket.
|
Some grinding to make a flat area.
|
Both halves completely closed up.
|
And after some sanding.
|
|
|
|
|
Marking where to mill later on.
|
Bracket mounted.
|
Both halves sanded.
|
|
|
|
|
|
Both brackets mounted.
|
Enjoying the completed Command Module.
|
||
|
|
|
|
|
|
|
|
Front frame fitted
|
|||
|
|
![]() |
![]() |
The side brackets needs to be grinded hollow to fit
CM.
|
Brackets to lock the two halves together.
|
Originally two in the back were planned.
|
|
![]() |
![]() |
![]() |
![]() |
But without acces from the outside it is pointless.
|
Suddenly the two halves wouldn't come together...
|
...properly.
|
The flat bracket were too long.
|
![]() |
![]() |
![]() |
![]() |
So I made room for them.
|
It would have been easier cutting the bracket.
|
But now it fits... and a bolt through.
|
|
![]() |
![]() |
![]() |
![]() |
Grinding a little on the side bracket.
|
Comparing the two sides after a little grinding.
|
||
![]() |
![]() |
![]() |
![]() |
Now to the boxes inside the cages.
|
Working outside when the weather allows it.
|
Sides sawed.
|
Loose test fit.
|
![]() |
![]() |
![]() |
![]() |
Battens split into thinner battens... to save wood.
|
Side with thin battens.
|
Box without ends.
|
Another test fit.
|
![]() |
![]() |
![]() |
![]() |
Work space indoor.
|
Bettens for the ends.
|
One end...
|
...and the other end.
|
![]() |
![]() |
![]() |
![]() |
Test fit...
|
...a bit too tight it showed.
|
Disassembling to correct.
|
Now there's just a little space.
|
![]() |
![]() |
![]() |
![]() |
Marking the square holes for the
transverse loadbearing beam. |
That's about right.
|
Jigsaw.
|
Ready for a test fit.
|
![]() |
![]() |
![]() |
![]() |
Perfect fit.
|
Now... piercing all the way through.
|
In place.
|
Maybe a magician could use this!?
|
![]() |
![]() |
![]() |
![]() |
Both beams in place.
|
A lot of tubes makes a criss-cross pattern.
|
Test of one gable in place.
|
A look from the other side. Boxes done!!!
|
NOW... for the first time...! The
eagle shall be assembled in its full length of 7.50 meter or almost
25 feet.
|
|||
![]() |
![]() |
![]() |
![]() |
Collecting parts from all over our house.
|
Most are in the garage.
|
Two cages in place.
|
|
![]() |
![]() |
![]() |
![]() |
Spine coming down.
|
Laid on top of the two (four) cages.
|
It all raised up on saw horses.
|
Body boxes fitted.
|
![]() |
![]() |
![]() |
![]() |
The two transverse beams fitted along with the pods.
|
Lars Skovmand are looking when it is gonna fit.
|
Two legs and feet in place.
|
and the final two.
|
![]() |
![]() |
![]() |
![]() |
Boosters.
|
The roof of the passenger pod.
|
Passenger Pod done.
|
Gotta remove this shelf to make room for the CM.
|
![]() |
![]() |
![]() |
![]() |
There!
|
Getting the CM ready.
|
And the front frame.... will it hold?
|
The CM hinged down
|
![]() |
![]() |
![]() |
![]() |
The 55 kg CM would like to pull out the front frame.
|
Temporary fixed with strips.
|
All done without direction boosters.
|
Direction boosters added!!!
|
![]() |
![]() |
![]() |
![]() |
Mid section... the passenger pod.
|
A view from one shoulder pod to another.
|
A view from the road to our double garage.
|
Now hollowing up the side hinges.
|
![]() |
![]() |
![]() |
![]() |
Step by step hollowing the surface with angle grinder...
|
...until it fits.
|
Looking good.
|
|
![]() |
![]() |
![]() |
![]() |
A hole drilled
|
in bith brackets of course
|
||
![]() |
![]() |
![]() |
![]() |
Now drilling into the CM for later use.
|
Fitting the bolt.
|
||
![]() |
![]() |
![]() |
![]() |
Check!
|
The landing gear need to come down a little
|
This area needs to be opened up.
|
Dissassembling the elbow/arm.
|
![]() |
![]() |
![]() |
![]() |
Marking.
|
Grinding.
|
Removind the teeth.
|
|
![]() |
![]() |
![]() |
![]() |
Need some more opening up.
|
Same method.
|
||
![]() |
![]() |
![]() |
![]() |
Too low now.... but it will come a bit up again.
|
To be continued.....!
|
||
![]() |
![]() |
![]() |
![]() |
Template drawed for the inserts of the main boosters.
|
Template cut...
|
...and placed. A little bigger.
|
Now on to the 6mm plywood.
|
![]() |
![]() |
![]() |
![]() |
Jigsaw ready, steady...
|
Some time and concentration later. The 16 edge holes.
|
And the center holes also done.
|
The final fit will be a little higher in the booster
bells.
|
![]() |
Weekend February 19th + 20th 2022 - a status assemble,
without the Command Module,
for television (DRTV) that came visiting (see below). |
![]() |
|||||
April 23rd 2022 - Second assemble once again for television
(TV2) that came visiting.
Now with the Command Module attached. |
|
|
|
|
I found this roll of old cable warning band.
|
Along with the pvc tube from an old outdoor lamp...
|
...it made the perfect fit for a distance part.
|
Test.
|
|
|
|
|
Then I could go on with the next three.
|
Which made four in total.
|
But they needed to be gripped inside the bells.
|
So I made these sockets.
|
|
|
|
|
Mounted in the center of the bottom of the pot.
|
It gripped perfectly.
|
Now the four booster bells are almost done.
|
|
|
|
|
|
The oblong engine pods in the engine section.
|
I also made from the wide warning band.
|
Gaffa tape and filler glue hold it all together.
|
Now I just need something 'spherish' for the ends.
|
|
|
|
|
Used globes!!!
|
Cut in two halves...
|
...and narrow bands added...
|
...they made a perfect job.
|
![]() |
![]() |
![]() |
![]() |
I made this bracket template of wood (as usual).
|
But at Kurt's shop I got some aluminum.
|
Cut i smaller blocks.
|
...and shapes.
|
![]() |
![]() |
![]() |
![]() |
They began to look like something
|
The curves...
|
...I made on a large band grinder, which made the
item extremely HOT.
|
Meanwhile Kurt made the other parts for me.
|
![]() |
![]() |
![]() |
![]() |
Bolts added.
|
And thread cut.
|
For these sticks.
|
Now they are almost ready to fit the pods.
|
![]() |
![]() |
![]() |
![]() |
But one of the parts...
|
...shall be welded onto the engine frame.
|
Perfect!
|
Some of the weldings had to be grinded off,
to make room for the bracket part. |
![]() |
![]() |
![]() |
![]() |
The brackets needed to be curved - with the grinder.
|
To fit the globes curve. Perfect.
|
And then...
simple holes drilled in the sockets of the engine bells |
Ready to try on...
|
![]() |
![]() |
|
|
Along with the rods and brackets on the frame.
|
Looks great.
|
Last I needed to adjust the holes
in the ends of the globes to fit the rods. |
Each disc are different shaped.
|
|
|
|
|
Glue added.
|
Some has to be fitted vise versa.
|
Test.
|
Test... all good.
|
![]() |
|
|
![]() |
Two of the pods (top and bottom) needed to have two
grooves cut to be able to fit correctly.
|
That did the trick.
|
Some extra filler-glue added
to hold the globe ends to the middle band. |
Alle four engine pods now in place!
|
![]() |
![]() |
|
|
The very first try with Edding silver paint spray
cans.
|
Second layer outside and first layer inside
on the four main booster bells. |
Now to some smaller plant pots.
These shall be used for four of the vertical boosters. |
Along with some cuts from my second hand tabletop.
|
|
|
|
|
Four blocks.
|
Used as base for the bells.
|
Cutting then from square to octagonal.
|
And further more to nearly round.
|
|
|
|
|
The band grinder takes the last edges.
|
I had to mill tracks in the blocks
to match the bottom of the pots. |
Several cuts around the top edge.
|
Ends up in this edge form.
|
|
|
|
|
Fits great.
|
Now the pot has to be cut down in size.
|
The shape begins to take shape.
|
The pots gets mounted to the base with screws.
|
|
|
![]() |
|
Last the crack gets some filler.
|
And smoothening.
|
Here are the four vertical bells all painted.
|
A closer look inside.
|
|
|
|
|
Three years ago I made the feet.
|
Time to take them apart for some maintenance.
|
See how dark sun makes the wood.
|
Now some glue on.
|
|
|
|
|
And then srew back on, but not the 'horse'.
|
It also has to be taken apart and glued well together.
|
Some gently strokes.
|
Brings it nicely together again.
|
|
|
|
|
No time to smoothening roughnesses away.
|
The underside...
|
...also get the treatment.
|
Same goes for the side corners.
|
|
|
|
|
Sanding tools.
|
Now filling up some cracks here and there.
|
Also more glue needed.
|
The screws also get filled.
|
|
|
|
|
all filled up.
|
And sanded.... finally ready for some paint.
|
I went straight ahead with my plan using Hammerite
both as primer and as finish. |
Not used to paint I was surprised to see how much
the wood sucked the paint in.
|
|
|
|
|
Took several coats.
|
Here are seen areas with two and only one coat.
|
Two coats all over.
|
After a third layer of thick Hammerite it looked quite
black.
|
![]() |
![]() |
![]() |
|
After giving the sides the same treatment...
|
...I just wanted to see how the Hammerite would act
when having grey Edding sprayed on t it.
The plan was to give it just a thin coat for a starter. But when I saw the result... how it popped up. I took a break considering if I will go with this non-original look. I haven't settled for anything yet. |
Step 1,2,3
|
and four feet done.
|
![]() |
![]() |
![]() |
![]() |
A piece of drain tube. I only needed 16 wrinkles.
|
Each cut seperately.
|
Think they might fit in here...
|
...when trimmed. Now I'm looking for a
slightly larger diameter of drain tube. |
![]() |
![]() |
![]() |
![]() |
Preparation before painting.
|
Gotta seal all cracks and fill all holes and grooves.
|
Oh the top is still loose. Gotta glued it on final.
|
And seal it.
|
![]() |
![]() |
![]() |
![]() |
Three leg pods filled.
|
Ready for some sanding.
|
Because all edges look rough.
|
Much better after.
|
![]() |
![]() |
![]() |
![]() |
Getting there...
|
...and there.
|
Where I have used OSB board needed a lot more filler.
|
And sanding.
|
![]() |
![]() |
![]() |
![]() |
Grooved plywood also ned extra attention.
|
Rub it on...
|
...like that.
|
Work area.
|
![]() |
![]() |
![]() |
![]() |
A corner done.
|
Holes after cams also need extra filling.
|
Alle around the trapez formed details.
|
Almost done... now to the Saturn V part.
|
![]() |
![]() |
![]() |
![]() |
Metal bolts removed.
|
Also the four small wings hasn't got glue on yet.
|
Well amount of glue.
|
Excess glue used to make smooth edges.
|
![]() |
![]() |
![]() |
![]() |
The fourth pod (which is truly the first proto type
pod)...
|
...needed a kilo of filler becaused it is
made of all OSB board. |
A lot filler to sand down.
|
Time...
|
|
![]() |
|
|
...passes...
|
...and finally all four pods are ready for primer
paint.
|
First coat of primer. First pod.
|
Second pod.
|
|
|
|
|
Third pod first coat.
|
Third pod second coat.
|
Fourth pod.
|
Eagle parts scenery on the terrace.
|
|
|
|
|
Pods primer paint drying on the terrace.
|
The pods also need protection from the inside.
|
First coat of special anti mould paint.
|
Cracks filled and second coat.
|
|
|
|
|
Bottom plate for the leg pods.
|
All four cut customized to each own pod.
|
For perfect fit.
|
Primer paint will come later.
|
|
|
|
|
Making a upside down test setup...
|
... on the terrace.
|
Fitting the heavy stainless legs.
|
Now ready to see how centered the legs are.
|
|
|
|
![]() |
They are pretty good centered.
|
Only had to cuat a slightly larger whole.
|
The landing gear plate will cover any uncenterness.
|
Looking promissing.
|
|
|
|
|
A third and final coat added.
|
Making an rubber-like surface.
|
Once again drying on the terrace.
|
Line-up.
|
|
|
|
|
After closing up the back of the Command Module, there
still remained to be routed some tracks.
|
Let's see if I can remember how to...
|
...use this in free hand.
|
Some correction made in hand afterwards.
|
|
|
|
|
Cam holes and other holes...
|
...and cracks needed to be filled. Just like the leg
pods.
|
So a couple of days later I was finally ready
to add some primer paint. |
I just rolled on... back...
|
|
|
|
|
...and front. This is the lower half of the CM.
|
A fine coat. Almost transparent.
|
Unseen unevenness showed up and needed filler.
|
The tracks also primed.
|
|
|
|
|
Side view (just to write something).
|
Now for the upper half of the CM.
|
Same procedure.
|
Exciting.
|
|
|
|
|
I used the end of a roller to get down into the tracks.
|
Various views after first coat of filler.
|
||
|
|
|
|
After second coat I began to see areas that I wanted
to correct. Here a tile that reached a bit too high.
|
And some unevenness in the curved surface
sanded down. |
||
|
|
|
|
We can't having rain water running into the CM.
So better close the top hole for the top disc. |
Back to cutting a lot of short sticks.
|
A pile of them.
|
Each one gets its own customized shape.
|
|
|
|
|
Like this one.
|
One by one...
|
...around...
|
...the circular hole.
|
|
|
|
|
Doesn't look waterproof yet.
|
Sanding and filler.
|
Getting closer. Done for now.
|
This track is where the bolt from one of the
side brackets goes into the CM. |
|
|
|
|
The other enteres right below the mid-board.
|
Gotta make a setup to be sure where to fit the two
nuts.
|
Here...
|
...and there.
|
|
|
|
|
Tools for the job.
|
Hammer and wood chisel
|
To make room for the nut.
|
It doesn't need to be bearing,
so the nut shall just be in place. |
|
|
|
|
Ready for some protecting paint inside the CM.
|
Just like the leg pods. I tell you....
|
A LOT of panel to paint in here...!!!!
|
|
|
|
![]() |
![]() |
I'm not sure why I made this setup.
|
Maybe just because it looked good.
|
Until I noticed this fold in the curved surface.
|
|
![]() |
![]() |
![]() |
![]() |
The lower half of the CM needed the same treatment.
|
Halfway through.
|
Better glue the supporting bars firmly on.
|
Seen here. For the lower (removable) triangular panels.
|
![]() |
![]() |
![]() |
![]() |
A little adjustment to the Gemini part #25
|
I want the tip to reach just a bit onto the tile next
to it.
|
Glue added in top for a start.
|
Glued on... and wait until dry.
|
![]() |
|
|
|
Then filled up with several layers of glue form beneath.
|
The mailman cam with some Plexiglas.
|
Tinted plexiglas.
|
I think it will look good.
|
|
|
|
|
But before... I needed to add a
thin batten to the windows section. |
Measured and cut in 22.5 degree.
|
I only need two, but they weren't just long enough.
|
Here loosely in place.
|
|
|
|
|
The bearing strong rounded batten
needed to be glued on. |
A lot of glue and a lot of pressure.
|
Ready for the Plexiglas that needed to be cut.
|
It reach a bit too high.
|
|
|
|
|
But now it fits.
|
The thin list also glued on.
|
Supporting screws. While the glue dried...
|
...I decided to prime the Gemini parts meanwhile.
|
|
|
|
|
Gemini parts #28 and #29.
|
#25
|
First coat... drying in the open.
|
Second coat.
|
|
|
|
|
When dried...
|
...the under side got a coat also.
|
Even though these will be glued onto the windows section.
|
The end gables needed the details glued on too.
|
|
|
|
|
I use the indispensable drawings of Chris Trice and
Daniel Prud'Homme for perfect placement.
|
Glue...
|
...and pressure.
|
The tile details in place all glued on.
|
|
|
|
|
The doors got a back board.
|
Screwed and glued in place.
|
Glue also used in edges as filler.
|
Time to deal with the ugly fold on the top of the
CM.
|
|
|
![]() |
|
Sanded down and add primer once again.
|
First coat.
|
Second coat.
|
A third coat is needed... but will have to wait.
|
![]() |
|
![]() |
![]() |
Another pain in my eyes were
the lower panels of the passenger pod. |
But first it too they had to be glued firmly onto
the sides of the passenger pod. |
And then some serious sanding.
|
First panel done... clearly shows the difference
between right and wrong. |
![]() |
|
|
|
Both panels made.
|
The grooved panles of the sides also needed
to be glued on. |
To stabilize it all.
|
One side.
|
|
|
|
|
Second side...
|
...glue...
|
...also works as a seal.
|
Both sides done.
|
![]() |
![]() |
![]() |
![]() |
I painted the Gemini #29 part with semi mat Hammerite,
but it was way too shiny.
|
Preparing spraypaint stands.... screws.
|
Then I add some Edding mat black spray.
|
Which looked much better.
|
![]() |
|
|
|
All done.
|
Back to the sides of the passenger pod.
|
I got an (old) idea, which needed a top batten.
|
Sawn lengthwise in 22.5 degrees.
|
|
|
|
|
Sawn in length.
|
Marking where to trim the door panel in the heigth.
|
Off came the door panel and on came the top batten.
|
Might as well glue it on right away.
|
|
|
|
|
Lots of glue.
|
And submerged screws that were filled afterwards.
|
Gluing the details onto the doors panels.
|
Second tile added to the first tile panel.
|
|
|
|
|
And temporarely lots of small screws
to keep it all in place. |
The other door had a large cam hole to be filled.
|
Once the cam hole were dry and sanded...
|
...same glue treatment.
|
|
|
|
|
The two sides with now free doors panels.
|
Back to the top list of the windows sections.
|
I had been speculated how to make the list curved.
|
Forth with the belt sander.
|
|
|
|
|
And then again... in free hand... holding my breath.
|
The result became satisfying.
|
Maybe not 100% partial circular...
|
...but since it wont even be seen, it will do fine......
|