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Ameri-Can
                     Booster parts

        Booster-parts.jpg (100846 bytes)

Except for the bulkplate, we didn't use any epoxy to build our booster. Any individual part can be removed for replacement in the field using a screwdriver. 

  In an effort to ease the entry of more fliers into the ARLISS program, a starter kit was proposed. We signed on to "guinea pig" the assembly of a fiberglass tube kit supplied by PML. During the assembly, it became apparent that we could build the booster using only screws and Pemnuts. The booster assembly does require careful layout to align the fins, rail guides and all the holes through the various components. It also requires over 50 8-32 fasteners and some special threaded inserts.             Booster Assembled

                  Booster.jpg (97347 bytes)

                   

                      Bulkplate

         Bulkplate.jpg (52364 bytes)

I wasn't happy with the threaded inserts in 1/2" plywood since this assembly had to support the entire booster during recovery. We laminated 2 plates together and added the thin 4" plate to center the motor tube. With 8 screws and inserts, this should support the weight.

          

                

                         Fincan

        Fincan.jpg (103631 bytes)
The 28 "broaching" Pemnuts inserted easily into .25" holes drilled cleanly through the FG tube. We used an 8-32 hex head screw with a flat washer to draw them in. We set the can in a Vee Block and drilled the final holes at high speed to keep the hole edges clean. It's hard to estimate the "push out" strength of the Pemnuts, but it's not likely any of them will ever fall out.

          

                        Tail cone

         Tail-cone.jpg (55494 bytes)

The tailcone assembly includes a 1/2" bulkplate, an Aeropack retainer and a very exotic, anodized cone provided by our Far East Outpost. We only used 6 of the 12 screws provided with the Aeropack retainer and used our own 8-32 inserts. Since the cone covers the knurls on the nut, we drilled and filed our retaining nut so we could use our Slimline wrench to remove it.

            
                   Nosecone

         Nosecone-inside.jpg (133685 bytes)

 Nothing magic here. We wanted to use the nosecone space for radios, GPS or future video mounting, so we made a removable bulkplate. Just install more threaded inserts, tack in the  centering ring with 5 minute epoxy, keep it level while drying and some final epoxy.

The 8-32 broaching inserts 94648A340 and the plywood inserts 92105A002 are available from www.Mcmaster.com  Standard fins from Tom Rouse www.rouse-tech.com . Motor retainer from www.Aeropack.net . Order the PML tube kit www.publicmissiles.com using Mike's very friendly xls order file file that lets you design your own section lengths. More info will follow as we build the forward airframe.

       
                     Avbay

Fully loaded bay. GWiz LCX on the left controls the flight with redundant back-up from the MC2. The MC-HiG and the AltAcc are along for the ride. Note the GWiz USB adapter plugged into the MC2.

          Avbay-full.jpg (111894 bytes)

 

         Modified USB Adapter

We added some right-angle headers to the GWix adapter so it could plug straight in to the flight computers. This let's us down-load data without removing the units from the Avbay

 

                                          GWiz USB adapter.jpg (18176 bytes)

                  08 Modification

In order to use the forward closure to anchor the recovery harness and to reduce wasted space, we cut 7.5" off the booster. 7" was removed from the fincan and the motor tube. One centering ring was eliminated and the forward bulkhead was machined into a centering ring. Sims indicate this change will add about 500' of altitude.