| Boddomuk Construction
Details: Boddomuk construction can be split into three
phases: airframe construction, pod construction, and final assembly.
NOTE: For the following instructions,
"Cement" implies the use plastic cement (such as Testor's Plastic
Cement) or any other adhesive that will effectively bond the flexible,
non-porous plastic that the baby bottles are made of.
"Glue" implies the use of yellow glue (alphatic resin, or
"carpenter's glue") or any adhesive that will effectively bond
cardboard, balsa wood, and paper.
1. Airframe Construction
1.1 Cut the bottom 6 mm off of the three baby bottles. Use a
band saw or a razor saw for this step. The bottles are too slippery, too tough,
and too thick to do this safely with a hobby knife.
1.2 Select which bottle will be the body. Make six tube fins
from the other two bottles by cutting the bottles into 37 mm lengths. Again,
use a band saw or a razor saw.
1.3 Cement two tube fins together, side-by-side with the ends
even. Set the assembly aside, resting on the sides of the tubes fins rather
than on the ends. Wait for the cement to dry. Repeat with the two remaining
pairs of tube fins.
1.4 Cement a pair of tube fins to the body bottle, extending 10
mm beyond the bottom cut edge of the body bottle. Cement another pair to the
body bottle and to the mounted tube fin pair. Cement the final pair to the body
bottle and to the mounted tube fin pairs. All tube fins must extend 10 mm
beyond the bottom of the bottom of the body bottle. Wait until the cement is
dry.
1.5 Wrap an adhesive label around the straw. Cement the
label-wrapped straw to the body bottle, aligned with a triangular gap formed by
two tube fins and the body bottle. This should provide enough clearance for
easy insertion of a launch rod between two tube fins.
2. Pod Construction
2.1 Cut centering rings from 1.5 mm thick paper board or
3/32" balsa wood. Each centering ring must have an inner diameter of 18.7
mm and an outer diameter of 52 mm. Sand the outside edge of the rings for a
tight fit inside the body bottle.
2.2 Punch or cut four 1/4" diameter holes, evenly spaced
around the BT-20 tube, centered 21 mm from one end of the tube. This end of the
tube is referred-to as the "top" end in following steps.
2.3 Glue the 5 mm (1/4") thick balsa block into the
"top" of the BT-20 tube so that it is flush with the "top"
edge of the tube. What is meant by a "nose block" is a balsa cylinder
whose diameter is the inner diameter of the BT-20 tube. It can be made by
turning it on a mini-lathe or by cutting an 18 mm circle out of a 1/4"
thick sheet of balsa wood.
2.4 Glue a motor block 60 mm (2 1/2") up the
"bottom" end of the BT-20 tube as follows:
a) Spread a bead of glue, 2" inside
the "bottom" end of the BT-20 tube.
b) Insert the motor block into the
"bottom" end of the BT-20 tube.
c) Push an expended 18mm motor casing,
into the "bottom" end of the BT-20 tube until 5 mm (1/4") of the
casing sticks out of the tube. Immediately withdraw the expended motor casing.
2.5 Make a 3 mm (1/8") mark, 65 mm from the
"bottom" end of the BT-20 tube. Cut a 5 mm (1/8") slit along
this mark. Insert one end of a motor clip into this slit.
2.6 Secure the inserted end of the motor clip to the BT-20 tube
by applying glue to one side of a 13 mm x 100 mm strip of kraft paper, then
wrapping the strip over the inserted end of the motor clip. A weaker
alternative would be to use a 13 mm x 100 mm strip of masking tape in place of
the kraft paper. The main purpose of this strip is to ensure that no exhaust
gases enter the parachute compartment, so masking tape should be fine.
2.7 Mount a centering ring 42 mm from the "top" end
of the BT-20 tube. Secure the ring with a bead of yellow or white glue.
2.8 Mount a centering ring 28 mm from the "top" end
of the BT-20 tube. Secure the ring with a bead of yellow or white glue.
2.9 Mount a centering ring 17 mm from the "bottom"
end of the BT-20 tube. Secure the ring with a bead of yellow or white glue.
This ring will squeeze the motor clip against the BT-20 tube.
3. Final Assembly
3.1 Sand the centering rings of the pod for a snug fit into the
body bottle of the airframe.
3.2 Assemble the parachute.
3.3 Tie the center of the 70 cm elastic shock cord to the
middle of the pod's BT-20 tube, using a square (or "full") knot.
3.4 Tie one end of the shock cord to one end of a 23 cm length
of twine (crochet, Kevlar®,
or shroud line).
3.5 Tie the free end of the twine to one of the airframe's tube
fins.
3.6 Tie the free end of the shock cord to the ring-end of the
snap-swivel.
3.7 Tie the parachute to the snap-end of the snap-swivel.
3.8 Assemble
the nose as follows:
a) Place a sealing disc on the mouth of
the body bottle, with the flat side against the mouth.
b) Place a nipple on the sealing disc.
c) Place a nipple retaining ring over the
nipple and sealing disc so that its threads engage the threads of the
airframe's body bottle. Screw the ring firmly in place.
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