Space Shuttle Launch Pad 39A with Challenger STS-6 (1:144)

• #1720 by llanitedave on 24 Sep, 2019 14:57
• Manfred, in addition to admiring your modeling skills, artistic talent, and addition to detail, your sharing of the results of your research are teaching me things about the Shuttle that I had never suspected before.  I had always thought of myself as a space geek, and I had read many things about the design and construction of the Space Shuttle, among other vehicles, but your work shows me quite clearly how little I actually knew.
  
  
  Thank you for this truly extraordinary journey you have embarked upon!
• #1721 by roma847 on 24 Sep, 2019 17:25
• Thanks Dave for your flattering compliments.
  
  That's great if you can get so much benefit from my work.
  
  You'll laugh, but I felt the same way in the beginning and I had to learn a lot, first of all these many technical Space Shuttle terms ...
  
  I also learn with every detail also constantly news about this ingenious technique.
  
  Therefore learning by modeling!
  
  
• #1722 by roma847 on 24 Sep, 2019 17:27
• Hello everybody,
  
  no sooner said than done! So I've sanded the Support plate between two nail files to a thickness of about 0,3 mm, and I have to say that I liked it better than before.
  
  
  
  
  
  
  
  
  Now, the bow had to be glued as exactly as possible between the Support Brackets, but unfortunately I had to remove the stencil, which had previously fixed the position of the bow.
  
  
  
  
  
  The crunchpoint here, however, is that the bow must be aligned with the Feedline,
  
  
  
  and the Umbilical Plate should lie flush against the opening of the Orbiter Door.
  
  
  
  To accomplish this, I drilled the end of the Feedline in the middle and inserted a piece of Nickel silver wire as Centering aid.
  
  
  
  
  
  In this way I succeeded, first to glue the Support plate at the Crossbeam and then the Feedline-bow with the Support brackets, which will make the further work on the parts of the Cable Tray-TPS cladding much easier, since nothing can slip anymore.
  
  
  
  Then I've bent an Evergreen Strip (0,4 mm x 0,5 mm) under hot air around a rod (Ø 3 mm) and glued one ring of it in front of the Support plate.
  
  
  
  Then I've scratched the so called Pivoting Support missing at Airfix and glued it just behind the Intertank. 
  
  
  
  But this is only one half of the Feedline Support, as one can see in this image, as there is still a clamping ring over it,
  
  
  Source: System Definition Handbook SLWT, Vol. I (Lockheed Martin)
  
  which should be much narrower than at Airfix existing ring, as the comparison with the original photo shows, so I would have to modify these rings also a bit.
  
  
  Source: forum.nasaspaceflight.com (Jester)
  
  Then there are also missing the wider Rings in front of the supports, which I'll scratch too.
  So all in all a lot of odds and ends, which is still waiting for me. 
  
  
  
• #1723 by roma847 on 26 Sep, 2019 23:29
• Hello everybody,
  
  and now to the LO₂ Cable Tray along with the TPS Segments at the transition to the LO₂ Umbilical Plate.
  As always, before the Scratch-building of assemblies and parts there is nothing like a thorough inventory and accurate detailed analysis. ... ...
  
  The beginning is again this photo for a better orientation, which helped me because of the direct side view already in the sizing of the Distribution box, on which I have marked the first three parts of this LO₂ Umbilical assembly.
  
  Directly behind the distribution box is with the Part 1 a trapezoidal support part whose dimensions (length L, and upper and lower width) I've determined by reference to the diameter of the LO₂ Feedline (Ø 3 mm).
  
  
  Source: georgesrockets.com (George Gassaway)
  
  On this rotated photo, one can see this here gray part a bit closer, whereby the linked original zoom is unfortunately rotated.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  Therefore, here is still a section in the original resolution, on which one can see that this part is directly connected with the Distribution box and with the LH₂ Cable Tray. 
  
  And directly behind the oblique branch (Part 3) runs from the Cable Tray, which is connected with the Part 2 and passes over the Parts 4/5 to the Umbilical plate. 
  
  
  
  Thus, only the width of the part  is missing, which I have determined from this photo, which allows me to scratch the Part 1. 
  
  
  
  In this picture one can see the cables coming out of the vertical strut, of which one part, as just described, runs up to the LO₂ Umbilical plate and the remainder to the LH₂ Umbilical plate.
  In this rear view, the Parts 3-5 are admittedly covered by cuffs, but one can nicely see the entrance of the LH₂ Cable Tray into the Vertical Strut.
  
  
  
  And in this order, I will now try to scratch these five parts step by step. 
  
  
• #1724 by roma847 on 05 Oct, 2019 21:04
• Hello everybody,
  
  and now to the Part 1, which is small, but looks relatively simple, although in this image it is half hidden by the Distribution box.
  
  
  Source: georgesrockets.com (George Gassaway)
  
  After I had punched it with the Chisel cutter out of an ABS Plate (1 mm) and smoothed the edges, it was glued at this point, directly in the corner between the Distribution box and the Cable Tray,
  
  
  
  as one can see in these two images.
  
  
  
  
  
  Then it went on with the Part 2, whose shape one can only partially see in the photos, which has made the determination of the dimensions more difficult. Therefore, here again for a better distinction the color-coded Parts (1-6) with their partially hidden contours.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  In the next photo, it looks like Part 2 is directly adjacent to the green end part of the Crossbeam (Ball interface fitting), what I first assumed, but which is not the case.  On the other side, it is directly adjacent to the LO₂ Feedline Bracket, what one can clearly see in the zoom.
  
  
  Source: NASA
  
  And from this image I have determined some dimensions of the parts, whereby in my experience for the determination of Heights one should also use a Reference height, and for Widths accordingly a Reference width too. 
  
  
  
  Since this is still not enough to be able to scratch the parts, I've analyzed this already several times shown photo (rotated) for the remaining dimensions, which is very well suited because of its high zoom resolution.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  However, this image is very confusing due to the many dimensions, which is why Part 2 can be seen here again separately.
  
  Strictly speaking, the bottom of the part is not flat, but has down this triangular extension, but which I have not marked here and will suppress, since with about 0,4 mm it should be almost "invisible" and can be safely neglected ...
  
  
  
  With these dimensions, I've then tried to scratch the part, whereby I first wanted to place it in an Evergreen strip (1 mm x 2 mm),
  
  
  
  but which seemed a bit too puny to me. Therefore, I will start another trial with an ABS Plate (1 mm) too.
  
  
  
  Previously I had drilled the opening for the GO₂ Press. Line (Ø 0,4 mm) into the Umbilical Plate and threaded the Nickel Silver Rod on a trial basis. 
  
  
  
  That should be enough for today. 
  
  
• #1725 by roma847 on 08 Oct, 2019 10:13
• Hello friends,
  
  today first again the experiment with Part 2 on a ABS Plate (1 mm), in which the slope should come out better than with the narrow Evergreen profile (1 mm x 2 mm). This time I have also taken into account this triangular extension on the bottom, which could be eliminated if necessary.
  
  
  
  The punching with the Chisel cutter went relatively well, so that the contour had to be filed then only slightly,
  
  
  
  what was again the same tricky procedure as the first time, because the part was barely could kept between the fingernails, but only in the tweezers tip, and even then slipped again and again. 
  
  
  
  In this image, one can see both parts in comparison, whereby the new part looks much more precise, whereby the lower extension is about 0,5 mm.
  
  
  
  And this is roughly the mounting position right next to the outer LO₂ Feedline Bracket, 
  
  
  
  which of course I have tested by laying up the part, and what looks pretty good for now. 
  
  
  
  
  
  Only at the point marked in red, I have to take away a little bit of the Crossbeam (Ball Interface Fitting), so that the narrow strip can advance a bit further, so that the tip of the part will be lined up precisely with the Feedline Bracket.
  
  
  
  Next, with Part 3, the probably most complicated assembly group of the LO₂ Umbilical comes along, which presumably will be built from several components.
  
  
  
  With that, in particular, the connection point of the channel running diagonally forward to the LH₂ Cable Tray must be determined even more precisely, which unfortunately is in hiding and so far could only be hinted at. 
  So all in all, a rather tricky matter in a confined space, which is why every handle wants to be well considered.
  
  
• #1726 by roma847 on 12 Oct, 2019 23:59
• Hello everybody,
  
  let's continue with the adjustment of Part 2, for which here beside the Crossbeam (Ball Interface Fitting) the announced narrow recess was cut out with the Mini saw blade.
  
  
  
  And as one can see, it's only a small cut, but leads to a clear improvement!
  
  
  
  Speaking of Original arrangement, I'm not sure anymore when I take a closer look at my black and white reference photo of the tank ET-8, which as is well known was to be the firstly flown Lightweight Tank (LWT), that was used since STS-6. Only at STS-7 was used a Standard Weight Tank (SWT) once again, for whatever reason.
  
  Unfortunately, the resolution of the photo is not exhilarating even in the zoom, and the area of interest to me is in the dark and is unfortunately also obscured by the Vertical Strut. 
  
  
  Source: forum.nasaspaceflight.com (Jester)
  
  But if you bend your eyes and look more closely, one recognizes, I believe, that especially the obliquely upwards running part of the Cable tray behind the support (Part 2) seems to be much narrower than on the previously considered images, which however, from later missions, where starting from STS-91 the Super Lightweight Tank (SLWT) was used, which had been modified again.
  
  
  
  To the following photo I will still inquire DaveS, from which mission it originates.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  And this photo shows the ET-122 at the last mission of the Endeavor (STS-134).
  
  
  Source: NASA
  
  Let's see if I can get some more information from DaveS, because sometimes he still has cool photos in his hindquarters, which have already solved some riddles. 
  
  
• #1727 by EG on 13 Oct, 2019 00:19
• I don't know if he has them in his hindquarters my friend, I think he keeps them in a nicer place (chuckle) but that being said, he does have the shots no doubt...
  
  And you sir, certainly know how to make use of them!!!
• #1728 by roma847 on 13 Oct, 2019 04:38
• Thanks EG for your nice private coaching and sorry for my poor English, but that was the suggestion of my smart Google translator ... Maybe one should better say that he sometimes has still cool photos up in his sleeve ... (Source: https://www.dict.cc) 
  
  
• #1729 by roma847 on 13 Oct, 2019 23:26
• Hello everybody,
  
  and DaveS' answer was not long in coming. He can not remember the mission from which his great photo came from, but as far as he knows, the Cable trays did not change during the Shuttle program and remained same from ET-1 (STS-1) to ET-138 (STS-135), which I did not want to believe at first.
  
  Because similar to here on the ET-8-Photo,
  
  
  Source: forum.nasaspaceflight.com (Jester)
  
  also on this photo of ET-129 (STS-126) at first glance the obliquely rising CT part (red arrow) in front of the middle strut seems to be lower than the horizontal part (yellow arrow) behind the strut.
  
  
  Source: NASA
  
  And also on this great photo of DaveS it looks similar at first. This photo gives the widest possible insight to below the Crossbeam, where one can see the further course of the cable tray very well.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  And so my previous perception is obviously an optical illusion, as I have now recognized in the zoom, if one waits until the zoom bar disappears at the bottom of the screen.
  
  
  
  In it one can see a dark area in the lower part of the oblique rise, which I have not recognized so far.  This is evidently a dark taped area similar to that at the top of the CT bow below the plate (Part 4).
  It becomes even clearer if one goes to 100% zoom in full-screen mode.
  
  
  
  And if one takes a closer look at this image of the ET-129, one can see the same dark lower part in the zoom.
  
  
  Source: NASA
  
  Therefore I suppose that also the Cable Tray on the ET-8 looked exactly the same, only that one could not see the area even in the zoom, especially because it did lay completely in the dark too.
  
  
  
  This confirms the statement of DaveS, that the Cable Trays did not change during the Shuttle Program, wherewith I now finally can go over to scratching the Part 3.
  
  In doing so, I will essentially focus on the following known images.
  
  
  Source: NASA
  
  
  
  All I have still to do is think about how to proceed in the most appropriate way.
  
  In any case, I will scratch the bow and the slant as separate parts and then connect. Since the bow with 1,5 mm x 6 mm x 4 mm is relatively small, the question arises, whether I am file out the whole part, or just the actual bow (Part 3.1), and then glue on the two tiny Parts 3.2/3.3? 
  
  How do you think about it?
  
  
• #1730 by roma847 on 14 Oct, 2019 22:21
• Hello friends,
  
  because the bow incl. the TPS Cladding on the LO₂ Side compared to the one on the LH₂ Side is nearly "huge", as can be seen here at the ET-118 (STS-115),
  
  
  
  it would be an unnecessary and vain effort trying to file out the whole part, as for the LH₂ Umbilical.
  
  
  
  So I'm going to bend an Evergreen profile (1 mm x 1,5 mm) again using my proven Balsa-aided Bending Technique under hot air around a Balsa stencil. 
  
  For this I first printed this drawing as a template on a scale of 1:144 in order to search for a corresponding Balsa stencil for the bow,
  
  
  Source: System Definition Handbook SLWT, Vol. II (Lockheed Martin)
  
  and have actually found one in my Balsa collection. One only has to keep in mind that the Cable tray in the drawing has no TPS cladding and is therefore a bit thinner than in reality.
  
  
  
  And then it went to the Balsa-bending table, on which the rectangular profile was clamped in a known manner between two small Balsa boards.
  
  
  
  Thereafter, the Hot air gun was started and the rod bent under the stream of hot air around the template, fixed immediately and once more blown on hot again.
  
  
  
  After the bow could cool off for a while and this shape was "frozen", I removed the small board and could convince me of the success of the bend.
  
  
  
  And so I could go on,
  
  
  
  and have immediately marked the Length (6 mm) and the Height (4 mm) of the bow.
  
  
  
  Now I still have to determine the end point of the part in front of the Crossbeam. Then I also know how long the Part 3.4 may be and can then scratchen this.
  Anyway, I'm very satisfied so far and I hope it stays that way.   
  
  
• #1731 by roma847 on 17 Oct, 2019 17:18
• Thanks Ron and EG for liking.
  
  Hello everybody,
  
  next, I've cut off the two tiny Closeouts from an Evergreen strip (0,25 mm x 1,5 mm), as well as sanded a bit,
  
  
  
  and glued them on the bow (Part 3.1).
  
  
  
  With it then I have checked the arrangement of the bow together with the center support (Part 2) and the provisional Part 3.4 for which I used a Profile bar (1,5 mm x 1,5 mm),
  
  
  
  what already looked pretty neat.
  
  
  
  Here's for comparison the scale drawing of this arrangement,
   
  
  
  which I've provisionally laid on locally, in order to see if or how the size fits, which also looks quite well. 
  
  
  
  So far so good, but since with it neither the endpoint of the Cable Tray in front of the Crossbeam nor the length could be determined, I came up with the idea,  to bend a complete CT-Dummy out of a Strip (1,0 mm x 1,5 mm) and to test its location locally according to my previous measures.
  
  After that was done in no time,  
  
  
  
  I've marked the height up to the Umbilical plate (about 7 mm), as well as the distance to the slant (6 mm),
  
  
  
  where I've bent it after the upper cut.
  
  
  
  The length of the CT Dummy from the Crossbeam to the endpoint under the Umbilical plate I have measured with 11 mm. 
  
  
  
  And then I've tried this dummy locally, whereby the positioning was a pretty tricky affair.
  
  And as one can see, the part fits quite well,
  
  
  
  and hits roughly onto the slant of the LH₂ Cable Tray below the Crossbeam, which seems quite plausible.
  
  
  
  With these dimensions, I can now scratch the remaining parts on both sides of the previous bow.
  
  
  
  That's it for today.
  
  
• #1732 by roma847 on 20 Oct, 2019 06:54
• Hello friends,
  
  but with the attaching of further parts that's another story, which is why I've thought of everything twice again plenty, especially since it is in the combination of such filigree parts not to millimeters, but rather by decimillimeters. And wether at the end the exact installation dimension of the Cable Tray would come out is more than doubtful, or but coincidence. 
  
  Therefore, one does not get along without fitting, which is why it is better to proceed step by step, i.e. scratching one part at a time and preferring to test better safe than sorry to be able still to correct in between. 
  
  Thus, the CT-Dummy had done its duty and could be set aside.
  
  But already with to try on the parts one has a lot of trouble to bring these small parts into position and then measure distances, what one can see in this image. Because in order to lay up the profile bar for the slant next to the central support, I had to put (with breath hold) a spacer in between. 
  
  
  
  Therefore, it seemed appropriate to glue first the Center support (Part 2), so as to have a fixed point for the further procedure.  Before that, I've placed the support several times on the outer LO₂ Feedline Bracket and juggled back and forth, and finally made even smaller corrections (height/width) until I was satisfied with its position and then it could finally be glued.
  
  
  
  Because if the size and location of this support would not be right, would not fit the slant, as well as the subsequent bow too.
  
  
  
  And now, by laying on of the intended Profile bar (1,5 mm x 1,5 mm), I was able to more accurately determine the required length of the Slant (Part 3.4) than before, because the support could not slip anymore. But before I shorten the rod to the final length, I may be want to make a few minor modifications. At least the lower tip of the bar under the support should become still slightly bevelled.
  
  
  
  In order to be able to adapt the bow with the lower Closeout to the support, I had to first shorten a bit the upper part of the bow in order to attach it to the Umbilical plate and to be able to test the position.
  
  And also for this a special substructure was needed to get to the appropriate height. Above the black marking, it will then go on with the Parts 4-6.
  
  
  
  But as one can see, the front part with the Closeout fits quite well under the support, so now still only the front slant has to be made to fit.
  
  
• #1733 by roma847 on 22 Oct, 2019 00:04
• Hello everybody,
  
  well, this slanted front part of the Cable Tray(Part 3.4) really has it in it and has almost already become to a nightmare of my sleepless nights ...
  
  But meanwhile I'm of the opinion that one edge more or less  doesn't matter, and therefore I will be content with an approximate solution, especially since later one cannot see this part under the orbiter from the outside anyway.
  
  The biggest difficulty in interpreting the course of the contours in the front area was this red circled notch directly under the Center support, which I have yet still decided to do,
  
  
  Source: NASA
  
  which can be clearly seen again on this image section.
  
  
  Source: forum.nasaspaceflight.com (DaveS)
  
  And in this image one can also see the front area relatively well, where I will then orient myself during scratching,
  
  
  Source: NASA
  
  especially since this is only a short stub of about 5 mm length anyway, as one can see here.
  
  
  
  For the upper closeout, I've glued a Strip (0,25 mm x 1,5 mm x 3 mm),
  
  
  
  and the lateral closeout will follow next in a similar way, wherewith I will then content myself.   
  
  
• #1734 by EG on 23 Oct, 2019 10:32
• Brother, your approximations are like everyone else's carbon copy....
  
  99.9% of modelers wouldn't have even bothered....
  
  yours always...
  
  EG
• #1735 by roma847 on 23 Oct, 2019 16:59
• Thanks EG for your great compliment.
  
  I have said it already a few times, Boon or Bane? My Reference photos are to blame, because they are simply too good, that I could omit these nice details.
  
  Stay tuned, my faithful friend, and have fun.
  
  
• #1736 by roma847 on 27 Oct, 2019 22:18
• Hello everybody,
  
  in the meantime I have completed the remaining CT Parts (Parts 4-6) and glued the lateral edge onto the Slant (Part 3.4), that is made from Evergreen Sheet Styrene (0,13 mm), which is very thin but noticeably in contrast.
  
  The upper Disk (Part 6) is the same size as on the other side Ø 2 mm x 0,3 mm, and for the Slant (Part 5) and the Plate (Part 4) I have each used an Evergreen strip (1 mm x 1,5 mm).
  
  
  
  For gluing the disc on the slant, it was again fixed centrally between two steel rulers. 
  
  
  
  
  
  
  
  So far, so good.
  
  Next, I actually wanted to glue the Slant (Part 3.4) under the Center support (Part 2). But before that I glued the two rings on the bow of the LO₂ Feedline, which one can see in this photo.
  
  
  Source: NASA
  
  For this I wrapped an Evergreen Strip (0,5 mm x 0,5 mm) around a steel rod and held it under the Hot air gun, then I've cut out two short segments, which were glued between the two Feedline Brackets, wherewith these details get done now too.
  
  
  
  Then the slant was glued under the Center support, which extends to the LH₂ Cable Tray under the Crossbeam. And that was also the expected delicate matter both for my eagle eyes (+ Headset magnifying glass), as well as for my quiet hand to place this part with the tweezers exactly as possible straightaway, what fortunately worked quite well.
  
  
  
  After that I immediately tried on the bow and checked its position in the contact zone under the center support and to the slant, and corrected its position still minimally.
  
  
  
  
  
  At the rear end of the slant now this CT-bow must be glued, as well as on it the remaining CT-Parts (Parts 4-6), which hopefully still fit in between.
  
  Following that, I will then bend the end piece of the GO₂ Press. Line also from a Nickel-silver rod (Ø 0,4 mm), which goes from the last Ice Frost Ramp up to the Umbilical plate, but for the time will being not glued. The remaining GO₂ Press. Line forwards up to the LO₂ Tank will then later be installed as a separate line.
  
  
  Source: NASA
  
  That's it for today, dear folks, and thanks for watching.
  
  
• #1737 by roma847 on 28 Oct, 2019 22:13
• Hello friends,
  
  after the bow has fitted quite well, I then have glued it under the center support with the front slant and aligned immediately.
  
  
  
  
  
  When trying on the upper assembly group Parts (4-6), I unfortunately had to realize that this was a bit too high and did not fit into the gap.  Therefore, the upper disc had to be removed again and the slant slightly shortened. After gluing a new disc, the group was then glued into the gap and also aligned.
  
  
  
  
  
  
  
  Now I'm jolly glad that I also managed this tricky LO₂ Umbilical, and am amazed that it  come off quite well, as I think. And since it is quite similar to the original, the considerable effort was well worth it.
  Next, as already announced, I will now bend and adjust the end fitting of the GO₂ Press. Line.
  
  
• #1738 by llanitedave on 30 Oct, 2019 23:06
• Manfred, if you work to any finer scale, you’re going to need an electron microscope!  I continue to be amazed.
• #1739 by EG on 31 Oct, 2019 05:45
• I have to agree dave, the talent here on display is mesmerizing...
  
  And to think, it is all coming from photographs, almost no line drawing....
  
  A master at work....