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#1020 by roma847 on 19 Aug, 2016 12:42
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Hello everybody,
meanwhile shape and seat of the nozzle pipe have been slightly modified, and for facilitating the tests I have tinkered a little TSM Balsa dummy to avoid unnecessary stress for the final TSM.
And hence to the tricky nozzles that had already made some headache a year ago dealing with the nozzle pipe on the rear wall of the SSME chamber.
Because my former manufacturing method of the individual nozzles in retrospect appeared as being too complicated, I have fiddled about another solution that should be less stressful.
While on the former almost twice as long tube (approx. 32 mm) were arranged six nozzles, on this tube (about 16 mm) under the TSM this time even eight nozzles with Ø 0,5 mm are to be accommodated, resulting in distances of about 1.4 mm.
For the marking and drilling I have benefited of a PE template (cmkkits.com) for 0.8 mm rivets, which was very helpful.
First I have pre-drilled with Ø 0,3 mm and then after that with Ø 0,5 mm.
The idea was to insert somewhat longer rods (about 7 mm, Ø 0.5 mm) into the holes, to glue them with EMK and thereafter to bend all together at one time under moderate hot air in the final form, and then to cut.
Therefore, the pipe had to be clamped again in a balsa corset, what has proven itself in similar form already several times.
The required clear height of the nozzle bows results from this close-up on the basis of the reference diameter of the nozzle tube (Ø 2.0 mm) to about 0.6 mm,
Source: NASA
which is why I now have clamped a corresponding brass rod with Ø 0,6 mm directly behind the nozzle rods.
And now the entire row could be bent, the Proxxon Gun in the right hand, and with Left the rods were carefully bent down with the balsa slat,
what has worked well straight away.
After the nozzle lengths were marked,
they were cut off on the steel ruler with the cutter chisel.
And then it looks like this.
And from this result, I am now surprised, because this was not necessarily to be expected.
Now I can calmy turn to the nozzle openings, which can tolerate a little bit Tuning.
Tomorrow I will test this nozzle pipe on the MLP.
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#1021 by roma847 on 19 Aug, 2016 14:09
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Hello together,
despite the interesting divertissement by the Olympics
the SSWS pipes were continued in the meantime.
Today, the second 9'' transition was scratched, which had to be bent again initially.
Although the processes are now already familiar, the difficulty is to make the transitions as identical as possible.
These are the individual parts up to the two rods for support pillar.
After the filigree U-shaped substructure has been scratched, the difficile assembly of the parts followed, which was quite stressful again.
And so the couple was complete,
and could be tested on the MLP.
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#1022 by roma847 on 19 Aug, 2016 14:11
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Although the provisional fastening of the outlets with Pattex is also such a tiresome game of patience and does not long hold out,
for the imposing overall impression the effort is worth to me, which is why I have brought out the Rainbirds again.
So much for today.
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#1023 by roma847 on 19 Aug, 2016 14:18
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Hello everybody,
after the outlets in the SRB chambers except for the two 36'' feed pipes and the nine missing pipe supports are done, it is now time for the last two outlets behind and under the TSM's.
This initially affects the section behind the rejuvenation of the 24'' ring line to 16'' (Ø 2.5 mm) just before the corner of the TSM beside the SSME chamber to 12'' (Ø 2.0 mm), such as re-measurements have shown.
Source: NASA
On this pipe sitting eight small bent nozzles, which should have a diameter of about 0.5 mm.
Source: NASA
In order to adapt this outlet I initially have bent for simplicity a continuous piece of rod Ø 2.0 mm, ranging from the ring line to the end of the nozzle tube under the TSM, which is sitting on two support angles. This way possibly necessary corrections of position and mounting of the nozzles should be made easier, and only when everything matches this nozzle tube is cut at the last rejuvenation and connected to an intermediate piece with Ø 2,5 mm, which begins at the ring line (Ø 4,0 mm).
Here this continuous pipe is bent, which begins at the ring line.
And this is the first test that looks already times quite good,
although the tube seems to be a little too close to the TSM corner,
what I'll be watching in more detail once more.
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#1024 by roma847 on 19 Aug, 2016 14:29
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Hello everybody,
meanwhile shape and seat of the nozzle pipe have been slightly modified, and for facilitating the tests I have tinkered a little TSM Balsa dummy to avoid unnecessary stress for the final TSM.
And hence to the tricky nozzles that had already made some headache a year ago dealing with the nozzle pipe on the rear wall of the SSME chamber.
Because my former manufacturing method of the individual nozzles in retrospect appeared as being too complicated, I have fiddled about another solution that should be less stressful.
While on the former almost twice as long tube (approx. 32 mm) were arranged six nozzles, on this tube (about 16 mm) under the TSM this time even eight nozzles with Ø 0,5 mm are to be accommodated, resulting in distances of about 1.4 mm.
For the marking and drilling I have benefited of a PE template (cmkkits.com) for 0.8 mm rivets, which was very helpful.
First I have pre-drilled with Ø 0,3 mm and then after that with Ø 0,5 mm.
The idea was to insert somewhat longer rods (about 7 mm, Ø 0.5 mm) into the holes, to glue them with EMK and thereafter to bend all together at one time under moderate hot air in the final form, and then to cut.
Therefore, the pipe had to be clamped again in a balsa corset, what has proven itself in similar form already several times.
The required clear height of the nozzle bows results from this close-up on the basis of the reference diameter of the nozzle tube (Ø 2.0 mm) to about 0.6 mm,
Source: NASA
which is why I now have clamped a corresponding brass rod with Ø 0,6 mm directly behind the nozzle rods.
And now the entire row could be bent, the Proxxon Gun in the right hand, and with Left the rods were carefully bent down with the balsa slat,
what has worked well straight away.
After the nozzle lengths were marked,
they were cut off on the steel ruler with the cutter chisel.
And then it looks like this.
And from this result, I am now surprised, because this was not necessarily to be expected.
Now I can calmly turn to the nozzle openings, which can tolerate a little bit tuning.
Tomorrow I will test this nozzle pipe on the MLP.
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#1025 by Ronpur50 on 19 Aug, 2016 14:40
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WOW!!!
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#1026 by roma847 on 19 Aug, 2016 19:24
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Thanks Ron, and hello together,
and here are two images of today's try-on on the MLP. 
This is all still pretty shaky, but otherwise fits quite well.
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#1027 by Davp99 on 22 Aug, 2016 17:00
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It's Like Dotting All the ' i 's & Crossing All the ' t ' s....It is all these Fine Details that will make this Project really Stand Out..
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#1028 by roma847 on 22 Aug, 2016 23:22
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Thanks Dave for your nice compliment,
but I can not leave out this crazy stuff,
because it's like a drug.
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#1029 by roma847 on 24 Aug, 2016 23:14
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Hello everyone,
meanwhile it went on with the other nozzle tube under the LH2 TSM.
At first it was drilled again,
then the 0.5 mm rods for the nozzles were inserted and glued with MEK.
Then again followed my standard clamp procedure for the bending process with inlaid brass rod.
The bending was followed by the reduction of the supernatants, wherefore the already finished nozzle tube was very helpful for measurements and therefore was clamped next to it. 
Then the supernatants were separated on the steel ruler.
And these are the two nozzle tubes, left for the LOX TSM and right the new for the LH2 TSM, except for the mirroring almost identical twins.
And so it went on the fly to the 6'' outlets which run behind the two TSM's from the ring line, then under the SRB Blast Shields
Source: NASA
and end on the back walls of the SRB chambers.
Source: NASA
After the required dimensions were determined, then followed the bending of the rods (Ø 1,0 mm) around a corresponding template, which is by now become routine.
Now the appropriate length of the inclined portion only had to be found which one can measure unfortunately nowhere directly due to the oblique arrangement, not even from my little sketch of the true to scale side view.
So only remained Trial & Error with slightly oversize, what then looks so.
Although the bow is is indeed a little too wide and should become a bit narrower,
but from the arrangement it fits already quite good.
And the test fitting of the new nozzle tube right in the picture around the TSM dummy is also okay.
That's it for today, tomorrow is another day.
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#1030 by Davp99 on 26 Aug, 2016 18:44
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Manfred, until your build, I never thought of the Mobile Launcher as a real Monster, just of itself..Never really looked at All the hardware, All the pipes, Conduits and Cables Trays and etc etc etc..Thank you
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#1031 by roma847 on 26 Aug, 2016 23:08
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Thanks Dave,
yeah, the MLP on the Crawler is really a monster, but I like them both with all their crazy details.
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#1032 by Ronpur50 on 27 Aug, 2016 00:05
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I know, I just imagined it as a big box with the TSMs on it. I knew there were rainbirds and some pipes around the edges of the cutouts, but never did I ever look at it in this detail!
I can't wait to see what you do with the Challenger! -
#1033 by roma847 on 27 Aug, 2016 05:52
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Thanks Ron for watching,
I know that many modelers are only interested in shuttles and rockets and less for the technique around it.
The shuttle stack is another chapter, but has still to wait for a while ...
BTW, the shuttle has not nearly as much details as the MLP with the Crawler or the Launch tower, which are much more complex with numerous crazy details and not less interesting.
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#1034 by JMS on 27 Aug, 2016 06:12
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Beautiful job.
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#1035 by Marge Inovera on 30 Aug, 2016 18:34
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Manfred, I can't log into ARC and I'm glad you're posting here! This latest solution of yours for the nozzle tubes is an excellent example of problem solving!
The care and precision you are working to is a real pleasure to watch come together!
I'm still watching!!
Pete -
#1036 by roma847 on 30 Aug, 2016 22:54
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Thanks Pete for your nice words,
I also can't log into ARC Forums with Google Chrome. I have informed the admins already three days ago, but so far no one has replied, obviously nobody feels responsible for security issues, that's an evidence of incapacity.
BTW, but with MS Internet Explorer one can log in, no problem.
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#1037 by roma847 on 01 Sep, 2016 12:05
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Hello everybody,
today also the second 6'' outlet of the couple has been added, and the other two outlets for the right side I have also still bent. For the clamping rings I have wrapped lead wire Ø 0,3 mm around a 1 mm rod and then cut with a razor blade.
And even on these thin pipes there are the already known nipples, for which I will use Styrene rods with approx. Ø 0.2 mm.
Source: nasatech.net
And here the pipes have been "welded" to the ring line and threaded under the Blast Shield. 
This fits in so far as quite well into the picture,
now I have to fit in only the correct adapter pipe with the rejuvenation on 12'' (Ø 2.5 mm) at the end of the 24'' ring line (Ø 4,0 mm) and to cut the nozzle tube (Ø 2,0 mm) just behind the TSM corner, then the strand is finally complete.
Source: NASA
And how could it be otherwise, these rejuvenations stand on a short support, which is constructed similar to the two pillars under the 9'' transitions at the other end of the ring lines, and therefore they are also on the to-do list.
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#1038 by roma847 on 02 Sep, 2016 22:44
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Hello everybody,
nothing is impossible, and therefore I want to show you still on the fly my announced attempt with the nipple on the prototype of the 6'' outlet (Ø 1 mm). 
The tiny hole on the bend I have predrilled with my smallest drill with Ø 0.2 mm. And then I have been amazed, as I have found in my remeasuring of the 0.3 mm rods that they are a little undersized, approx. Ø 0.25 mm, and accordingly might fit well. 
After the little rod was glued with MEK and shortened, the outlet with the tiny nipple looks like this.
And so also this detail on the thinnest outlet has been mastered, especially as the clamping rings are far less problematic.
But Stop! Do you notice anything?
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#1039 by b0objunior on 03 Sep, 2016 07:30
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Dude, this is GREAT!!!
