Descon Nose Nugget

Scratch - Nose Nugget {Scratch}

Contributed by Bob Fortune

Manufacturer: Scratch
(Contributed - by Bob Fortune)

T' Nose Nugget
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A relatively simple way t' install a payload in a 3.9" Ace Nosecone

This technique will work for any nosecone brand. Well, blow me down! Blimey! Blimey! Blimey! I used an Ace NC because I had one kickin' around. Begad! Blimey!

Parts List:

  • One Ace Nosecone (NC)
  • One 4" by 16" piece o' balsaply (or equal)
  • One 4" by 4" piece o' 1/4" plywood for bulkhead (BH)
  • One 18" piece o' 3/8" wooden dowel
  • One Print Out o' Ace Nosecone interior
  • - Download Part One
  • - Download Part Two
  • 3 ounce fiberglass (glass)
  • Epoxy laminatin' resin (like Systems 3 or West Systems)
  • Cyanoacrylate (CA)
  • 1 U-bolt
  • 1 1" section o' 4" airframe tubin' (for retainer ring)
  • 4 each #8 panel clips (from auto parts store)
  • 4 each #8 by 1/2" screws
  • 3M 77 (or equal) Spray Mount Adhesive
Assembly Instructions:

Download t' 2 templates and print out on your printer. Arrr! Blimey! There are 1" square boxes on each template t' indicate correct sizing, matey, you may have t' fiddle with your printer output t' get t' correct size. Begad! Arrr! These are .gif images.

Once you have t' templates sized and printed cut them out and match t' two halves t' t' match line shown. The entire cone is drafted though you don't need them both if you don't intend t' make t' entire nosecone a payload section. My design only has t' last 6" or so o' t' cone interior as payload. Well, blow me down! Well, blow me down! T' lines are thar so you can cut to size as you choose. Aye aye! Ya scallywag!

Usin' a spray mount adhesive, matey, glue t' template t' t' balsaply. Arrr! Aye aye! Cut t' template t' rough shape. Aye aye! Ahoy! Usin' a sander or rasp or whatever, shiver me timbers, sand t' template t' it's final shape. Well, blow me down! Don't attempt t' cut t' template out dead-on t' t' lines, it's much easier t' get it close then sand t' get it perfect. Blimey! Avast, me proud beauty! While you have this template cut your fiberglass cloth to fit, shiver me timbers, you need one piece this size. Begad! Once you have t' balsaply cut t' size, cut along t' dotted line. This is where the dowel goes. Blimey! Aye aye! These two parts I am callin' "wings" for t' sake o' clarity. Arrr! Take one win' and use it as a template t' cut an additional wing. This third win' becomes a "strong back" t' support t' two wings and dowel in t' cone. Well, blow me down! Usin' this win' as a template cut an additional two pieces o' glass, shiver me timbers, but a bit oversize - maybe an inch wider. Set t' glass aside for later use. Arrr!

On t' second template thar be a bulkhead template. Glue this t' 1/4" ply and cut out. Avast! Take t' Ace nosecone and trim off t' bottom part (where t' screw top thin' is). Cut it right where t' wall intersects t' base. T' 1/4" ply bulkhead slides in here. Avast, me proud beauty! Test fit t' bulkhead and sand as necessary t' get a good fit. Well, blow me down! If the bulkhead is oversize it will balloon t' shoulder o' t' NC and t' airframe (AF) tube won't fit. Test it with a section o' AF you intend t' use. Ya scallywag! Drill a 3/8" hole in t' center o' t' bulkhead. Avast, me proud beauty! Drill two holes t' receive the U-bolt. Avast! Begad!

I made t' dowel poke out t' tip o' t' nosecone because it was fun t' do. Blimey! Arrr! It's nay critical, me hearties, you can simply make t' dowel shorter. Ahoy! T' purpose o' t' tip protudin' is t' center t' payload section in t' nosecone, a job the wings if cut properly can do.While you have t' nosecone in hand, whack off t' tip o' it so a 3/8" hole is developed. Begad! I used a bench grinder for this and it takes some grindin' and fitting. T' fit is important so make sure it's nice and snug, take your time.

Fit t' dowel into t' NC so an inch or so protrudes from t' tip. Add a bit o' yellow glue t' t' dowel just at the base o' t' shoulder line Slide t' bulkhead over t' dowel and into t' shoulder. Avast! T' dowel is now square t' the NC if you trimmed t' tip properly. Ya scallywag! Aye aye! CA t' dowel t' t' bulkhead and remove by pullin' on t' dowel protrudin' from the bulkhead. Clamp this is a vise or somethin' handy t' keep it from movin' around. Blimey! Usin' yellow glue, me bucko, me bucko, glue t' three wings t' t' dowel. T' two wings in t' same plane are flush with t' tangent o' t' dowel cross section. Begad! Avast! T' third win' is at 90 degrees t' these wings. Let dry. Begad!

Get t' 1" piece o' airframe and cut it into 3 pieces. Avast, me bucko, me proud beauty! One piece will be 180 degrees and t' other two 90 degrees. Ya scallywag! You will need t' remove some o' t' tube t' make it fit inside t' wings, me hearties, a pair o' strong scissors works well. Blimey! When fittin' t' pieces, me hearties, make sure that they are nay flush with t' edge o' t' bulkhead. Begad! Aye aye! Hold them back off the edge (towards t' dowel) as t' panel clips need t' clear t' shoulder o' t' nosecone. Avast, me proud beauty! Glue these pieces t' the bulkhead and t' t' wings. Aye aye! Ya scallywag! This becomes t' retainer ring. Avast, me proud beauty!

Test fit t' part in t' nosecone. Ahoy! Blimey! If it doesn't fit, arrr, shiver me timbers, sand all t' parts t' make it fit. It needs t' slide in and out nicely. Ya scallywag! Blimey! Blimey! Blimey!

Get your 3 pieces o' glass cloth. Well, blow me down! Mix up some epoxy. Avast, me proud beauty! Get a little paint brush. Blimey! Brush on a coat o' resin on the face o' t' wings. Blimey! Ya scallywag! Place t' glass on t' face o' t' wings. Arrr! Avast! Wet out t' glass so it disappears. Arrr! Begad! Turn part over and repeat on strongback with two pieces o' glass. Aye aye! Usin' t' brush in dabbin' motions, shiver me timbers, stipple t' glass onto t' surface so all t' glass is in contact with t' balsaply. Aye aye! This is easiest as t' resin begins t' set and becomes tacky. Avast, me proud beauty! Try to eliminate all t' air bubbles. Begad! Allow t' cure t' B stage (this is when t' epoxy is kind o' rubbery) and trim t' glass to t' correct size. Begad!

Find out where t' hole in t' panel clip lines up on t' retainer ring. They are all different so you have to fit and see. Avast! Generally t' hole with t' clip in place is about 1/2" down from t' U bend in t' clip. Make a note where t' hole hits t' retainer ring. Avast, me proud beauty! Install t' U-bolt at this time. Begad!

Usin' t' shoulder o' t' NC as a guide, ya bilge rat, mark t' base o' t' nosecone on your airframe. Avast, me proud beauty! Install t' payload section into t' NC. Begad! Install t' NC on t' airframe you intend t' use. Blimey! Usin' t' mark you just made and your measurement o' t' panel clip on t' retainer rin' drill 4 holes 90 degrees from each other around t' airframe. Blimey! Avast, me proud beauty! Blimey! If they are nay dead on, ya bilge rat, t' airframe will only align with t' holes as drilled. Begad! Aye aye! Blimey! Make a mark on t' NC and on t' airframe where t' holes line up properly. Begad!

Remove t' nosecone. Remove t' payload section. Ya scallywag! Blimey! Ahoy! Blimey! Install t' panel clips. Aye aye! Blimey! Well, blow me down! Blimey! Reinstall t' nosecone. Blimey! Blimey! Begad! Blimey! Reinstall the payload section. Begad! Blimey! Ahoy! Blimey! Install 4 #8 screws, T' nosecone ain't comin' off for nothin'. Arrr! Blimey! All t' parts are workin' together to keep t' electronics you install on t' board in place and in t' nosecone. T' U-bolt will take a major hit and will transfer t' load t' t' airframe through t' panel screws and retainer ring. You may have problems if you use some serious noseweight so take care. Begad! Blimey! Deployment shock loads can be upwards o' 15 or 20 g's makin' a one pound noseweight suddenly equal t' a 20 pound noseweight. Arrr! Blimey!

Install some electronics, shiver me timbers, a power source, a shunt for your pyro, and go flying!

Flight Report

This nosecone flew with on a Binder Raptor on a J350. Arrr! Unfortunately t' motor ejection charge went early due t' an improper seal in t' forward closure delay well. (Pilot error) It was supposed t' be a long delay t' back up t' electronics but it be way short. Well, blow me down! : ) T' charge went off while t' rocket be still boostin' but the thin' held together, t' chute deployed, and no damage be done. Well, blow me down!

Bob Fortune
© September 2000



Pictures

1_On_2manyfins.jpg
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2_BH_view.jpg
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3_Push_the_button_NF.jpg
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4_Face_view.jpg
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5_Strongback_view.jpg
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6_looking_down_NF.jpg
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7_Side_x_side_NF.jpg
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