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

[Spaceman]

Thanks Stuart for sharing your memories with us.

Let’s still reminisce for a moment before continuing with my build report.

Back then, I was in close contact with Scott, who fell in love with NASA’s Space Shuttle Program as a teenager and followed it through all the missions, from the maiden flight of Columbia to STS-1 (1983), back when the stack still had the white External Tank (ET-1), to Atlantis’ final mission STS-135 (2011).

Here one can see the 21-year-old rookie Scott Phillips in the man-tube entering the LH2 tank through the ET-1 manhole (Ø 36") to inspect the sensors.

Source: Scott Phillips, Remove Before Flight

And here’s a legendary photo taken before Columbia’s launch on the Mobile Launcher Platform (MLP-1) on Launch Pad 39A, showing the closed manhole marked by Scott, through which he, as the last man, exited the External Tank in 1983 after completing the inspections. Among those visible are US Vice President George H.W. Bush between the first two astronauts, Robert Crippen (right) and John Young (left) and his wife.

Source: NASA/Scott Phillips

Here one can see the young long slim Scott Phillips with his arm outstretched, jumping next to the camera after Columbia’s Lift-off.

Source: NASA

And here Scott Phillips some years later with Crippen and Young with their signed Space Shuttle Models.

Source: Scott Phillips

And finally Scott Phillips in his workshop turning a Shuttle model,

Source: Scott Phillips

where the chips were flying.

[amoz02t]

Wow! Wonderful!!

[Spaceman]

Hello everybody,

let’s go step by step on our way to the goal, here are the next images of Michael Key’s 3D modeling.

As one can see in this image, he has omitted both the six plates in the door and adjusted their size, as well as he had corrected the distances of the and the CP from each other and from the Thrust Panel.

Source: shapeways.com (Michael Key)

The position of the CP, however, remained unchanged and still sits too high up, although I had already marked it in this last image,

Source: NASA

what one can also see in this photo.

Source: forum.nasaspaceflight.com (Jester)

Furthermore, it is noticeable that the bottom plate of the large LO2 Fairing admittedly is flush with the stringers, but not that of the small LH2 Fairing,

Source: shapeways.com (Michael Key)

which is still to be corrected, according to the following photo, but hopefully will not cause any problems.

Source: NASA

Then here are two more images of the small supports of the GH2/GO2 Press. Lines (2’'), first with the indicated lines,

Source: shapeways.com (Michael Key)

and here the final design without the lines, whereby the thin wires (Ø 0,3 mm) will separately be inserted later and covered with small caps.

Source: shapeways.com (Michael Key)

Now I hope that these last changes can also be considered by him, according to which an upload of the 3D model to Shapeways nothing would stand in the way.

But Michael Key wanted to be honest and told me, that there are some very small parts in this model that could possibly overstrain Shapeways’ possibilities, so the model might not pass their inspections the first time around. That would be normal, and Shapeways would let him know the problem, which he would correct.

That’s why I’m very curious, but initially his modified model is still due.

[Johnnych01]

This is just such a great thread to follow, an amazing build, unbelievable back story full of in depth first hand info and knowledge …. and here with people who were in the program … Brilliant !!

[Spaceman]

Thanks John, it always fascinates me to remember all of this too.

It’s nice if I can entertain you.

[Spaceman]

Hello everybody,

and now back to the 3D Intertank, where Michael Key is coming down the stretch after his considering of my last little changes.

And just now another NSF friend (DaveS) was coming out with this interesting photo of the Access Door at STS-31 (1990), unfortunately again without source.

But after I’ve found the image in Google, I recognized it from the URL, according to which it comes from the collection of George Gassaway, which I know by now.

Source: georgesrockets.com (George Gassaway)

And since I found a similar photo of the STS-30 (1989), I suspect that since the use of the Leightweight Tanks (LWT), starting at STS-6, such doors were installed, which apparently also had a foam insulation.

Source: georgesrockets.com (George Gassaway)

For this also militates this photo of my friend James MacLaren, which also shows such a door in the background. The image shows the Challenger on Pad 39-B, probably during the preparation for her fateful final mission STS-5-L (1986), what I still will find out.

Source: nasaspaceflight.com (James MacLaren)

Consequently the photo used so far for the 3D modeling shows a Graphite-Composite door, as has been used later on the Super Lightweight Tanks (SLWT),

Source: NASA

like here at the STS-133 (2011).

Source: NASA

For Michael Key’s 3D Modeling this realization is coming too late unfortunately, but which is not a problem, because I can glue this door with the two handles later on, especially since it is very small (9 mm x 8 mm),

as one can see here.

[Spaceman]

Hello everyone,

now it goes on with the 3D Intertank journey, which went into the next round, which keeps me in suspense.

Unfortunately I have yet overlooked an important detail that was not yet correct in the last images of Michael Key’s 3D model and consequently could not remain, what was to be seen 14 days ago in this image.

Source: shapeways.com/forum (Michael Key)

I had circled the part already, but at first I was only interested in the bottom plates of the two Fairings.

After I had Michael Key pointed this and had been once more showing the still too high Carrier Plate, he wanted to get back to with the final model for the final checkup, for what I specifically had asked him befor a possible upload to Shapeways.

Almost at the same time DaveS came up with this, so far unknown Access Door, how it most likely had looked like at ET-8 during STS-6.

Source: georgesrockets.com (George Gassaway)

About this I have informed Michael Key and told him at the same time that he should not change the door, because I could scratch this little detail as well.

After that he surprised me with his final Intertank version, in which he had even considered this door in addition to the lower located Carrier Plate, which of course I was pleased.

Source: shapeways.com/forum (Michael Key)

And here are further pics of his 3D model:

After I have begun to wonder about the arrangement of the two Fairings as well as the PAL Ramps and Cable Trays,

at this close-up my hair suddenly stood on end.

Apart from the somewhat too crude shape of the big LO2 Fairing, both fairings are next to each other almost at one height, but what is not true, although in turn was clearly visible on previous photos, but what apparently he has not registered and consequently not so implemented.

In reality, the arrangement of the fairings however looks like as at these two photos.

Source: NASA

Source: NASA

But the bafflement was following, by telling me at the same time that he had uploaded his model to Shapeways, which would have allowed everybody to order immediately, but what was agreed otherwise, by the way, for EUR 58 (WSF) or EUR 91 (FUD), but with these errors.

And in the 3D panorama view of the Intertank in his Shapeways Shop, this error was also clearly visible (see red dashed line).

Furthermore, I wondered about the tapering shape till the top of the two PAL Ramps and the resulting gap to the Cable Trays, which is not true.

Source: shapeways.com (The Aerospace Place)

Then I have immediately communicated Michael Key this change requirement on the basis of these earlier photos,

Source: NASA

Source: NASA

what I have marked on this image again.

Source: shapeways.com (The Aerospace Place)

Because of these mistakes, I have asked him to remove his offer from his shop site immediately, which he then has done.

A controversial point is still the form of the fairings and the arrangement of the GH2/GO2 Press. Lines, for which he has sent me this picture, in which I have marked my changes in red.

Source: shapeways.com/forum (Michael Key)

And as one can see in these photos, the two Press. Lines should run closer to the LO2 Feedline.

Source: NASA

Source: georgesrockets.com (George Gassaway)

Slowly but surely, but somehow we’ll crack the hard nut like the squirrel.

As far as the current state.

[Spaceman]

Hello everybody,

Michael Key has still modified the shape of the two Fairings a bit, which looks really better now.

Source: shapeways.com/forum (Michael Key)

And the arrangement of the details now agrees fairly well with the original and can therefore remain so.

Source: NASA

And since the wall thickness of the LO2 Fairing is only 0,25 mm (1:144), we have agreed on to insert no opening for the LO2 Feedline (Ø 3mm), so I can glue the line directly.

With that Michael Key has now reached the home stretch and the final is heralded.

[Johnnych01]

The research on this is really next level.

[Spaceman]

Thanks John for staying tuned,

you know my endurance, I’ll never give up.

[Spaceman]

Hello friends,

we are just before completion.

At first still this small addendum, which I have reached out non-binding to Michael Key, without knowing whether he would go into rapture in view of my previous special requests.

But I thought, asking does not cost anything, either-or?

On this image of the STS-6 one can see these two areas, in which the Stringer-Valleys are filled up with Insulating foam, which would perfectly complete the already nicely detailed Intertank.

Source: retrospaceimages.com (J. L. Pickering)

The white part (left) is the RSS Antenna, as well as an Aerodynamic Vent in the middle of the right-hand area, as I found it in George Gassaways ET collection,

here at STS-37 (ET-37),

Source: georgesrockets.com

as well as here at STS-36 (ET-33).

Source: georgesrockets.com

And what should I tell you, in his final version, he has even implemented these two details.

Source: shapeways.com/forum (Michael Key)

Source: shapeways.com/forum (Michael Key)

This surprise he really succeeded.

[Spaceman]

Hello everybody,

after the events have almost happened in quick succession today, it is now done.

But always nice in turn step by step.

After Michael Key had uploaded his model to Shapeways, he sent me the link, from which the following images are taken, which are showing the awesome Intertank in different views, as one can see.

Based on the large number of pictures you can already see how much the end product thrilled me …

Thereupon I immediately ordered a print for 95,99 EUR incl. shipping.

In the midst of the delirium of joy then came a friend from our Raumcon Forum with his damper regarding the shrinkage problems at FUD and FXD, as well as in connection with the costly stiffening rings, which one would have to consider.

Based on these legitimate hints, Michael Key responded immediately and after a few changes has uploaded his model again, and now lets print it 0,8% larger.

He also pointed out that one possibly might have to sand a bit, either on the printed Intertank or on the ET parts of the kit, but that would not be unusual and should be feasible.

However, as this model, with a wall thickness of about 0,7 mm, is quite thin, he would not recommend removing the stiffening rings. Instead, he has reduced their mass by enlarging the holes in the middle, which has fortunately resulted in a cost savings of about 20 EUR, that one can not complain about.

And those changes looked like this.

Thereupon I immediately have canceled my first order and reordered a new Airfix Intertank (1:144) for 71,83 EUR in FUD.

Source: shapeways.com (The Aerospace Place)

Now I hope that Shapeways can also print the part with all its details, wherefore all available thumbs are needed, to make it to a round matter in the end in the truest sense of the word.

[Spaceman]

Hello everybody,

my next sub-project will be the Ice/Frost Ramps on the LH2 External Tank, and I hope that Michael Key can help me with this as well.

Source: NASA

And so the ramps for the GO2/GH2 Press. Lines look like in detail.

Source: NASA

I know that my ARC friend Bill (niParts) has modeled a set of these Ice ramps (1:72), but in 1:144 they are unfortunately much smaller.

Source: shapeways.com (niParts)

In reality these ramps are 2’ x 2’ x 1’ , that means 2 mm x 2 mm x 1 mm for the ET (1:144).

The diameter of the LH2/GH2 Press. Lines is 2’’ = Ø 0,35 mm (1:144) and should be the reference.

The openings in the ramps are slightly larger, approx. Ø 0,5 mm, as one can see in this image.

Maybe that these very thin wall thicknesses could be a problem for Shapeways 3D printer?

[Spaceman]

Hi everybody,

Shipped!

Just now, I’ve got Shapeways’ pleasant message, that they have shipped the Intertank (€ 73,26).

Consequently Michael Key’s 3D model seems to have been print-ready.

Now I’m very curious what the Intertank will look like.

[Spaceman]

Hello everybody,

meanwhile, the long-awaited package of Shapeways has arrived, at first again only a feather-light box with lots of air in it, which was carefully let out.

And before the last shell fell, one could already see the object of desire.

Compared with the accustomed images of the 3D model, the Intertank looks at first glance rather inconspicuous, because one can not really perceive the details due to the semi-transparent FUD look and really must look very closely, especially as there is sticking a lot of supporting wax in the fine grooves of the Stringers and Ribs, which still has to be removed. But stable feels the part anyway.

But what has attracted my attention immediately was the fact that the inner support tube was missing, through which I want to thread the support rod for the SRBs, which surprised me a lot and I can not explain,

especially since the tube still was to be seen on Michael Key’s 3D model images,

as well as in the 3D view on Shapeways’ website, which is very strange …

Source: shapeways.com (The Aerospace Place)

The later-planned steel rod (Ø 1,5 mm) could not at first be inserted into the opening and pushed through, but after a few attempts it was still possible, albeit with some difficulty.

After this first disillusionment I’ve tried out the provisionally taped front part of the ET,

which let fit tightly onto the intertank.

And here are some more images with an attempt to catch some of the details but what was not easy.

Here is a look at the two Fairings as well as the PAL Ramps and Cable Trays, although the latters can hardly be recognized.

In contrast to the narrow fit of the front part, I noticed perceptible clearance of the parts when setting the Intertank onto the rear part of the ET.

But otherwise the part is coming out quite well, I think.

And I just when I wanted to put the Intertank together with the ASTC rings in my new ultrasonic bath for cleaning,

as I noticed that the rear inner ring was broken and had detached nearly over half the length from the inner wall, as if it had not been tied to it at all.

How this can happen is completely obscure to me, especially since the laser melts together the wafer-thin layers of powder when printing, really strange …

To this amazing finding and the missing inner tube I have to consult Michael Key and hear what he means, then we’ll see.

[Egilman]

Hey Brother…

Good to see you working on this again…

Miss you over on Spaceflight… (NSF)

Still doing wonderful work my friend….

Elmer

[amoz02t]

So sorry for the aft frame separation! Hope the Shapeways material responds well to thin super glue? This is where one would be trying the AnyCubic 3D printing Gray resin if you can get access to the STL file? Both materials are very brittle, but I like the smoother finish of the grey resin after print. Looking good! Please share more.

[Spaceman]

Thanks Elmer, my true friend, for looking in on me here in KitMaker too, cause you know the whole story from NSF already.

Once I’ve finished NASA’s Psyche Space probe, I’ll also be back on NSF with my STS-6 build log, promised!

The main thing is that you all have fun.

[Spaceman]

Thanks Stuart for staying tuned too.

You shuld know, that giving up is not an option for me.

Never!

[Spaceman]

Hi everybody,

now again to the missing inner tube, from which even Michael Key was very surprised, because when he has checked the number of parts of the model on Shapeways’ website, there was displayed it with “1”, which means, that everything is connected.

Then I looked at the 3D Panoramic view of the model at Shapeways’ website once more very closely and found a setting where one can see that the tube on both sides clearly is not connected to the inner wall of the tank, which will now be the main subject of my complaint to Shapeways next to the crack of the inner ring.

As Michael Key has told me, it would be Shapeways’ standard method of sending a reprint, whereupon I’d like to renounce because I don’t want to have a part with the same errors.

Instead, I should ask them for a refund and say that there are some other issues with the model, whereat I have informed the designer, who is ready to modify his model for a better version. Besides I could casually mention Shapeways’100% Satisfaction guarantee" with which they apparently advertise.

I have informed Shapeways about this today and hope for their goodwill, to grant me a refund, in order to get an improved Intertank with inner tube in the second attempt.