Embedded Files
The first job before any plastic was touched was to produce a scale 3D paper model of the CSM. This was a visual aid to help see where all the external details were in relationship to each other as i was finding it a little difficult from looking at a 2D flat drawing. I make extensive use of MicroSoft Excel to produce scaled prints. I have a template spreadsheet that contains a scaled rule, a screengrab is then imported and resized against the rule to give the required size
The first job before any plastic was touched was to produce a scale 3D paper model of the CSM. This was a visual aid to help see where all the external details were in relationship to each other as i was finding it a little difficult from looking at a 2D flat drawing. I make extensive use of MicroSoft Excel to produce scaled prints. I have a template spreadsheet that contains a scaled rule, a screengrab is then imported and resized against the rule to give the required size
This is part of a larger drawing from the Apollo set by David weeks. This was taken and resized to 1-32nd scale using microsoft excel
This is part of a larger drawing from the Apollo set by David weeks. This was taken and resized to 1-32nd scale using microsoft excel
The scaled prints were then glued to an old plastic washing powder tub to form the 3d paper model
The scaled prints were then glued to an old plastic washing powder tub to form the 3d paper model
Patterns printed to scale
Patterns printed to scale
The service module
The service module
The Command module placed on top of the service module
The Command module placed on top of the service module
The clear section was shimmed and pre-fitted, and the raised exterior details removed.
The clear section was shimmed and pre-fitted, and the raised exterior details removed.
The rear bulkhead was discarded and a new one fabricated. The new bulkhead includes a nut that is held in place with a small housing. This allows the engine bell to bolt to the body, with the rear heatshield sandwiched in between
The rear bulkhead was discarded and a new one fabricated. The new bulkhead includes a nut that is held in place with a small housing. This allows the engine bell to bolt to the body, with the rear heatshield sandwiched in between
Bulkhead marking out
Bulkhead marking out
Prefit to the body
Prefit to the body
Nut housing
Nut housing
Stiffeners glued in place, and a cap glued over the nut
Stiffeners glued in place, and a cap glued over the nut
One of the upgrades used on the service module was a photo etch and resin kit from New Ware . The set contains 108 parts-35 resin & 73 photo etch
One of the upgrades used on the service module was a photo etch and resin kit from New Ware . The set contains 108 parts-35 resin & 73 photo etch
Resin parts
Resin parts
Photo-etch
Photo-etch
The resin panels were marked out and fitted to the forward end of the module. The positions of the running lights were also marked and holes drilled for them
The resin panels were marked out and fitted to the forward end of the module. The positions of the running lights were also marked and holes drilled for them
Line up marking out
Line up marking out
The umbilical panel has a protrusion on the rear, so a section is cut out of the body for it to fit into
The umbilical panel has a protrusion on the rear, so a section is cut out of the body for it to fit into
Hole is marked and panel ready to fit
Hole is marked and panel ready to fit
Hole for running light
Hole for running light
Drilling jig used to make sure the holes were all in line
Drilling jig used to make sure the holes were all in line
Umbilical panel in place
Umbilical panel in place
The fibres optics were installed next.
The fibres optics were installed next.
Small guide tubes glued into place
Small guide tubes glued into place
Fibres installed into tubes and powered up to check for correct positions. There are two red, two green & four amber.
Fibres installed into tubes and powered up to check for correct positions. There are two red, two green & four amber.
Forward bulkhead installed. Four slots were cut in it to accommodate the four forward fibre tubes
Forward bulkhead installed. Four slots were cut in it to accommodate the four forward fibre tubes
Light check after the fibre was glued into place
Light check after the fibre was glued into place
Braces installed to support the fibres
Braces installed to support the fibres
Amber & Green Lights
Amber & Green Lights
The Rendezvous light was installed. This is a flashing light that was mounted on the service module. Fortunately the cycle of the flash quite closely matches the description of the real thing. NASA documentation and David Weeks drawing set were used to confirm the position, type and colours of the lights installed
The Rendezvous light was installed. This is a flashing light that was mounted on the service module. Fortunately the cycle of the flash quite closely matches the description of the real thing. NASA documentation and David Weeks drawing set were used to confirm the position, type and colours of the lights installed
The flashing light came prewired and all that is required is to extend the live and earth cables and hook them up to a power supply
The flashing light came prewired and all that is required is to extend the live and earth cables and hook them up to a power supply
The resin housing was drilled and a guide tube installed
The resin housing was drilled and a guide tube installed
A lens installed
A lens installed
A still from a video captures the light
A still from a video captures the light
Epoxy glue was used to cast a plug in the engine nozzle, to give a mounting point for the display bracket .
Epoxy glue was used to cast a plug in the engine nozzle, to give a mounting point for the display bracket .
A tube was bolted into place
A tube was bolted into place
A plug of glue poured in up to the seating washer
A plug of glue poured in up to the seating washer
A stiffening tube cut
A stiffening tube cut
A fit check of the stiffener against the heat shield
A fit check of the stiffener against the heat shield
the stiffener and a guide plate glued to the aft bulkhead
the stiffener and a guide plate glued to the aft bulkhead
Access holes drilled into the glue to allow the wires to run through
Access holes drilled into the glue to allow the wires to run through
The hole in the centre contains the nut to bolt the items together. The wires are for the service module running lights. Then the other two tubes run top to bottom through the module and are to carry the wires for the Command Module and the Lunar module
The hole in the centre contains the nut to bolt the items together. The wires are for the service module running lights. Then the other two tubes run top to bottom through the module and are to carry the wires for the Command Module and the Lunar module
It was around about this time that I realised i needed to make some more concrete plans for the lighting as all of a sudden extra holes and more wires kept appearing and i started to have a few doubts about whether or not i could physically fit everything into place, where the wire joints would be, and how i could power it up. With that in mind i set about designing a circuit. This gave me a better understanding of how many wires were needed. The flashing lights are put onto separate power supplies from the standard on/off lights, this was done on advice from the lady who supplied them. The reason being is that if a flashing light is on the same circuit and the batteries get low on power then the other lights may start dim and then go brighter in time with the flashers. All the lights were supplied by Jennifer Smith (JS Miniatures). Jennifer has been a great help and given me some really sound advice.
It was around about this time that I realised i needed to make some more concrete plans for the lighting as all of a sudden extra holes and more wires kept appearing and i started to have a few doubts about whether or not i could physically fit everything into place, where the wire joints would be, and how i could power it up. With that in mind i set about designing a circuit. This gave me a better understanding of how many wires were needed. The flashing lights are put onto separate power supplies from the standard on/off lights, this was done on advice from the lady who supplied them. The reason being is that if a flashing light is on the same circuit and the batteries get low on power then the other lights may start dim and then go brighter in time with the flashers. All the lights were supplied by Jennifer Smith (JS Miniatures). Jennifer has been a great help and given me some really sound advice.
To complete the lighting for the Service Module an EVA light was constructed from scratch
To complete the lighting for the Service Module an EVA light was constructed from scratch
NASA drawing of the EVA light
NASA drawing of the EVA light
Brass rod used to fabricate the stem, two bearing arms were soldered to the main rod. The mounting bracket was the photo etch part from the new ware kit. The spacer washers were punched out from sheet styrene
Brass rod used to fabricate the stem, two bearing arms were soldered to the main rod. The mounting bracket was the photo etch part from the new ware kit. The spacer washers were punched out from sheet styrene
the assembled unit
the assembled unit
The lamp head was taken from the kit. The front end was cut off, holes drilled from the front and underneath. A lens was glued to the front
The lamp head was taken from the kit. The front end was cut off, holes drilled from the front and underneath. A lens was glued to the front
The NANO led was threaded up through the main tube and powered up. Overall the light is a little "chunky" at the scale size, but the effect is good.
The NANO led was threaded up through the main tube and powered up. Overall the light is a little "chunky" at the scale size, but the effect is good.
During my next trip away at work i was able to fabricate the mounting bracket
During my next trip away at work i was able to fabricate the mounting bracket
When i got home from my six week trip away i was able to bolt the model together for the first time
When i got home from my six week trip away i was able to bolt the model together for the first time
Bolted together. The heat shield and the engine nozzle are 3D printed items from Micheal Key. The heatshield in this shot is the Versatile Plastic version
Bolted together. The heat shield and the engine nozzle are 3D printed items from Micheal Key. The heatshield in this shot is the Versatile Plastic version
A slightly different view showing the long threaded rod now installed at the forward end for securing the command module
A slightly different view showing the long threaded rod now installed at the forward end for securing the command module
The cream coloured panel is part of the new ware resin kit, the High gain Antenna support is from Micheal Key
The cream coloured panel is part of the new ware resin kit, the High gain Antenna support is from Micheal Key
Originally i bought the heat shield printed in Versatile plastic, I contacted Micheal and asked if the option of buying a version in fine detail plastic could be added.
Originally i bought the heat shield printed in Versatile plastic, I contacted Micheal and asked if the option of buying a version in fine detail plastic could be added.
A screengrab from Micheal's shop at Shapeways
A screengrab from Micheal's shop at Shapeways
The heat shield, here you can see the drop down where the different materials are offered. The price of the fine detail is significantly higher.
The heat shield, here you can see the drop down where the different materials are offered. The price of the fine detail is significantly higher.
There are a variety of materials offered by Shapeways, the "standard" is a very tough material they describe as versatile plastic. Reasonably detailed item can be produced with it, but its one downside is that is has a rally coarse grainy finish. To smooth it requires a lot of sanding and/or coats of undercoat, which can obliterate any surface details.
There are a variety of materials offered by Shapeways, the "standard" is a very tough material they describe as versatile plastic. Reasonably detailed item can be produced with it, but its one downside is that is has a rally coarse grainy finish. To smooth it requires a lot of sanding and/or coats of undercoat, which can obliterate any surface details.
The heat shield on the real spacecraft has a smooth shiny finish. To try and recreate shiny metallic surfaces on scale models a smooth finish is required, black gloss paint is applied, then the metallic paint on top. Shapeways also offer a fine detail plastic, which has a super smooth surface and more intricate details can be printed with it. Its downsides are increased costs and it is a very brittle material that can be a nightmare to work with
The heat shield on the real spacecraft has a smooth shiny finish. To try and recreate shiny metallic surfaces on scale models a smooth finish is required, black gloss paint is applied, then the metallic paint on top. Shapeways also offer a fine detail plastic, which has a super smooth surface and more intricate details can be printed with it. Its downsides are increased costs and it is a very brittle material that can be a nightmare to work with
Researching the model has meant i have spent a lot of time looking at a great deal of pictures, and learnt a great deal more of how the real thing was designed, manufactured and assembled, also how it worked.
Researching the model has meant i have spent a lot of time looking at a great deal of pictures, and learnt a great deal more of how the real thing was designed, manufactured and assembled, also how it worked.
One area of the model that appeared to lack any real detail at all was the area at the rear of the service module where it was bolted to the rest of the spacecraft. On the real space craft when one portion has done its job and was no longer required explosive charges were detonated and this cut and separated the two sections. The explosive charges are not always placed exactly where the two sections are joined, meaning that when they had done the job there is still a part of the discarded section attached. I decided to design and have a circular ring/band printed to replicate this.
One area of the model that appeared to lack any real detail at all was the area at the rear of the service module where it was bolted to the rest of the spacecraft. On the real space craft when one portion has done its job and was no longer required explosive charges were detonated and this cut and separated the two sections. The explosive charges are not always placed exactly where the two sections are joined, meaning that when they had done the job there is still a part of the discarded section attached. I decided to design and have a circular ring/band printed to replicate this.
Location on the service module
Location on the service module
On the picture above everything above the XA 938.00 line is the Service module (the silver-grey area). The white area below is the SLA. The two parts were severed at the separation plane. This meant that the structure between these two points remained in place attached to the service module after separation
On the picture above everything above the XA 938.00 line is the Service module (the silver-grey area). The white area below is the SLA. The two parts were severed at the separation plane. This meant that the structure between these two points remained in place attached to the service module after separation
A drawing was made, and scaled down to 1-32nd sizes
A drawing was made, and scaled down to 1-32nd sizes
A 3d rendering of the ring
A 3d rendering of the ring
NASA information
NASA information
There is a service and command module on display that was an unused leftover from the Apollo program. This is a great resource. Whilst investigating the aft ring i became interested in the other end a saw another band that was slotted, and and stepped up in diameter from the service module. When the spacecraft is launched there was a snug fitting cover over it called a Blast Protective Cover. The purpose of the band is to provide a surface to which a flexible silicone seal is attached. This seals the gap between the two pieces to give protection to the electronics and wiring that are mounted on the Service module front bulkhead from the weather, when the spacecraft was sat on the launch pad. It would also give a sealed area for the first phase of the launch
There is a service and command module on display that was an unused leftover from the Apollo program. This is a great resource. Whilst investigating the aft ring i became interested in the other end a saw another band that was slotted, and and stepped up in diameter from the service module. When the spacecraft is launched there was a snug fitting cover over it called a Blast Protective Cover. The purpose of the band is to provide a surface to which a flexible silicone seal is attached. This seals the gap between the two pieces to give protection to the electronics and wiring that are mounted on the Service module front bulkhead from the weather, when the spacecraft was sat on the launch pad. It would also give a sealed area for the first phase of the launch
A close up of the slotted band
A close up of the slotted band
A shot of CSM on display
A shot of CSM on display
A drawing of the band, this was taken and turned into an STL file, from which a 3D print could be made
A drawing of the band, this was taken and turned into an STL file, from which a 3D print could be made
A 3d rendering of the band
A 3d rendering of the band
Another close up
Another close up
The band as produced from Shapeways
The band as produced from Shapeways
A trial fit of the band
A trial fit of the band
Fine adjustments to the spacecraft are made by small rocket engines called thrusters mounted in clusters around the service module. They are mounted on removable sections that are called RCS doors. The new ware kit contains photo etched plates to represent these. After looking at flight photographs the ones supplied by New Ware did not match the Apollo 9 version for hole patterns and length. After a lot of head scratching and measuring, and a bit of educated guesswork I came up with a set of drawings which Brian Usher turned into a scaled 3D CAD drawing, from which a set of photo etch were produced
Fine adjustments to the spacecraft are made by small rocket engines called thrusters mounted in clusters around the service module. They are mounted on removable sections that are called RCS doors. The new ware kit contains photo etched plates to represent these. After looking at flight photographs the ones supplied by New Ware did not match the Apollo 9 version for hole patterns and length. After a lot of head scratching and measuring, and a bit of educated guesswork I came up with a set of drawings which Brian Usher turned into a scaled 3D CAD drawing, from which a set of photo etch were produced
Sizes for the new doors were calculated by scaling a picture so that a known dimension such as the height of the Service Module was correct at 1-32nd scale when printed. Extra lines were superimposed on the image, this was printed and the spacing of the lines measured. A lot of different images were used, and after taking into account discrepancies due to the angle the photo was taken at a set of drawings were made. This was also used to determine the size of the ECS radiators (the white areas seen at the aft end of the service module). Paper patterns of the panels were then cut out and taped to the model to see if they "looked" right when compared to flight images of the real thing
Sizes for the new doors were calculated by scaling a picture so that a known dimension such as the height of the Service Module was correct at 1-32nd scale when printed. Extra lines were superimposed on the image, this was printed and the spacing of the lines measured. A lot of different images were used, and after taking into account discrepancies due to the angle the photo was taken at a set of drawings were made. This was also used to determine the size of the ECS radiators (the white areas seen at the aft end of the service module). Paper patterns of the panels were then cut out and taped to the model to see if they "looked" right when compared to flight images of the real thing
RCS door panel on a service module under construction
RCS door panel on a service module under construction
The door panel shown on a flight image from Apollo 9
The door panel shown on a flight image from Apollo 9
Drawing produced using excel
Drawing produced using excel
Drawings turned into a CAD form, the red areas get etched to a depth of half the material thickness
Drawings turned into a CAD form, the red areas get etched to a depth of half the material thickness
The new door panels as received. There are four on a module, and they are in handed pairs
The new door panels as received. There are four on a module, and they are in handed pairs
Close up of a Left and Right hand door. The holes higlighted were placed there as locators for the RCS thruster pods. The surface finish imparted by the method used to etch the brass in this instance left a coarse grainy surface. This was ideal as it gave a good key for the paint that was applied later, and was not noticeably rough after the painting
Close up of a Left and Right hand door. The holes higlighted were placed there as locators for the RCS thruster pods. The surface finish imparted by the method used to etch the brass in this instance left a coarse grainy surface. This was ideal as it gave a good key for the paint that was applied later, and was not noticeably rough after the painting
As the build progressed the model was assembled to check various things, and as with each progressive step the model was getting heavier. This was putting a lot of load on the rear heat shield, which was then being twisted. Stiffening ribs were installed and whilst the glue was drying it was held straight
As the build progressed the model was assembled to check various things, and as with each progressive step the model was getting heavier. This was putting a lot of load on the rear heat shield, which was then being twisted. Stiffening ribs were installed and whilst the glue was drying it was held straight
All stiffened up
All stiffened up
Resin details glued in place, and ready for a paint
Resin details glued in place, and ready for a paint
Attention was then turned to the service module. You can see an ugly seam line below the masking tape
Attention was then turned to the service module. You can see an ugly seam line below the masking tape
And another seam
And another seam
And another one. I then decided that the best solution would be to apply a thin skin over the outside to give a nice finish, and to position the seam in the most unobtrusive place. Here all the surface detail has been shaved off and sanded flat. Fortunately i was able to remove the resin panels that were already installed without damage. The only one that remained was the umbilical panel, that was epoxied in place and there was no way to remove it without destroying it
And another one. I then decided that the best solution would be to apply a thin skin over the outside to give a nice finish, and to position the seam in the most unobtrusive place. Here all the surface detail has been shaved off and sanded flat. Fortunately i was able to remove the resin panels that were already installed without damage. The only one that remained was the umbilical panel, that was epoxied in place and there was no way to remove it without destroying it
Laying out the surface details , checking all the spacing's worked out nicely
Laying out the surface details , checking all the spacing's worked out nicely
The white sections are the ECS (Environmental Control systems) Radiators. On the original spacecraft they are moulded into the surface of the outer skin. The ones on the model are a bit chunky, and by my calculations are slightly oversize and in the wrong position. This coupled to the fact that the RCS doors that i made were longer, meant that something needed to be done to rectify them. I had always intended to remove the protrusions and to relocate them. Vincent Meen's solution was to 3d print new radiators and then to cut a section out of the body and sit the new parts in so that the radiator is flush with the skin. He then pre paints the model silver and the radiators white and fits them. I didn't think that i could achieve a good enough fit between the body and the radiators, and if i ended up having to fill the seams to get a decent finish that would negate the advantage of prepainting, and mean that masking and painting the detail would be needed. Another solution would be to glue strips to simulate the raised sections, then to mask and paint the white sections, this idea was abandoned due to the fact that i didn't think i could achieve a satisfactory finish. The method i decided to use was to make some radiators from the thinnest styrene sheet available with strips glued on to them. The ones seen here were some quickly lashed up prototypes. The strips were flat, this was substituted for half round on the finished items. Whilst not historically correct in the fact that the rectangular sections are laid on the surface I was happy to sacrifice that detail to achieve somthing that is more accurately sized and has a crisper finish paint wise
The white sections are the ECS (Environmental Control systems) Radiators. On the original spacecraft they are moulded into the surface of the outer skin. The ones on the model are a bit chunky, and by my calculations are slightly oversize and in the wrong position. This coupled to the fact that the RCS doors that i made were longer, meant that something needed to be done to rectify them. I had always intended to remove the protrusions and to relocate them. Vincent Meen's solution was to 3d print new radiators and then to cut a section out of the body and sit the new parts in so that the radiator is flush with the skin. He then pre paints the model silver and the radiators white and fits them. I didn't think that i could achieve a good enough fit between the body and the radiators, and if i ended up having to fill the seams to get a decent finish that would negate the advantage of prepainting, and mean that masking and painting the detail would be needed. Another solution would be to glue strips to simulate the raised sections, then to mask and paint the white sections, this idea was abandoned due to the fact that i didn't think i could achieve a satisfactory finish. The method i decided to use was to make some radiators from the thinnest styrene sheet available with strips glued on to them. The ones seen here were some quickly lashed up prototypes. The strips were flat, this was substituted for half round on the finished items. Whilst not historically correct in the fact that the rectangular sections are laid on the surface I was happy to sacrifice that detail to achieve somthing that is more accurately sized and has a crisper finish paint wise
The first "skin" being placed. I would have liked to have used one skin but ended up having to use two due to the size of sheet styrene i had. There are sheets big enough to do the job, but there were none available in the UK at the time
The first "skin" being placed. I would have liked to have used one skin but ended up having to use two due to the size of sheet styrene i had. There are sheets big enough to do the job, but there were none available in the UK at the time
3D printed Service module chassis
3D printed Service module chassis
During the build i designed a service module chassis that can be used to replace the kit version. Designed to have a skin wrapped around, and used in conjunction with the forward and aft rings that i designed.
During the build i designed a service module chassis that can be used to replace the kit version. Designed to have a skin wrapped around, and used in conjunction with the forward and aft rings that i designed.
The seam was lined up with the edge of a door
The seam was lined up with the edge of a door
The two sections of skin in place
The two sections of skin in place
Trimming and fitting the cable umbilical around the top band area
Trimming and fitting the cable umbilical around the top band area
Initial line up of the doors
Initial line up of the doors
The screw heads on the skin are replicated using "Archer fine detail resin rivets". Each rivet head is a small domed resin casting that is attached to a waterslide decal sheet. The row of rivets is then cut from the sheet soaked in water and then slid into place
The screw heads on the skin are replicated using "Archer fine detail resin rivets". Each rivet head is a small domed resin casting that is attached to a waterslide decal sheet. The row of rivets is then cut from the sheet soaked in water and then slid into place
On two sections of the skin are recessed holes that contain securing bolts, seen on this image as a double row near to the US flag, and running towards and through the ECS Radiators
On two sections of the skin are recessed holes that contain securing bolts, seen on this image as a double row near to the US flag, and running towards and through the ECS Radiators
Again by using known dimensions from the real vehicle, and counting the amount of holes between the two points it was possible to determine the spacing at 1-32nd scale
Again by using known dimensions from the real vehicle, and counting the amount of holes between the two points it was possible to determine the spacing at 1-32nd scale
A template was printed and attached to a strip of styrene
A template was printed and attached to a strip of styrene
The Dremel was used to drill out the holes
The Dremel was used to drill out the holes
Set up to drill the jig
Set up to drill the jig
The fiished jig was then taped to the model and used as a guide to drill the holes
The fiished jig was then taped to the model and used as a guide to drill the holes
The holes all drilled
The holes all drilled
A pattern was cut for the light shrouds
A pattern was cut for the light shrouds
This was then used as a guide to make four identical one to fit to the model
This was then used as a guide to make four identical one to fit to the model
The photo etch doors are glued to the skin, in the photo above i had a perspex tube with a piece of styrene attached so that i could perfect the method before doing it for real and possibly damaging the model. I tried a large selection of adhesives and finally went with Gorilla superglue, the Gel type. A jig was made to hold, and press the piece against the model whilst the glue cures
The photo etch doors are glued to the skin, in the photo above i had a perspex tube with a piece of styrene attached so that i could perfect the method before doing it for real and possibly damaging the model. I tried a large selection of adhesives and finally went with Gorilla superglue, the Gel type. A jig was made to hold, and press the piece against the model whilst the glue cures
The area around the door, and the front face of the door itself were securely taped up to catch any excess glue
The area around the door, and the front face of the door itself were securely taped up to catch any excess glue
On the whole position of panels and markings on the exterior of the CSM did not vary too much through its operational lifespan. Photo references of the position of panel access doors, and the paint colours are good, with the exception of sector 2 of the Apollo 9 SM. The only image i could find at the time was this very oblique view from one of the flight images. The three images below that are drawing are from three different sources. I then tried to see it was possible to see the panels on the photo. Of the seven panels on the drawings i manged to identify three on the photo. I posted this on the Apollo Spacecraft history page on FB, asking if anybody had more information.
On the whole position of panels and markings on the exterior of the CSM did not vary too much through its operational lifespan. Photo references of the position of panel access doors, and the paint colours are good, with the exception of sector 2 of the Apollo 9 SM. The only image i could find at the time was this very oblique view from one of the flight images. The three images below that are drawing are from three different sources. I then tried to see it was possible to see the panels on the photo. Of the seven panels on the drawings i manged to identify three on the photo. I posted this on the Apollo Spacecraft history page on FB, asking if anybody had more information.
David Weeks responded with this image, stating this was the only photo that he thinks exists of the Apollo 9 SM that partially shows Sector 2. It does confirm the existamce of one panel that i could not originally see. It also confirms that the top third of sector 2 was painted a white colour. The white section has been talked about in modelling forums, but this was the first hard evidence i have seen of it. As mentioned before David has produced extensively detailed drawings of the Apollo era Space vehicles and is widely recognised as a world class expert in these matters. His take on the other panels was that allthough he had never seen them the design and contents of that area of the vehicle was pretty unchanged from day one.
David Weeks responded with this image, stating this was the only photo that he thinks exists of the Apollo 9 SM that partially shows Sector 2. It does confirm the existamce of one panel that i could not originally see. It also confirms that the top third of sector 2 was painted a white colour. The white section has been talked about in modelling forums, but this was the first hard evidence i have seen of it. As mentioned before David has produced extensively detailed drawings of the Apollo era Space vehicles and is widely recognised as a world class expert in these matters. His take on the other panels was that allthough he had never seen them the design and contents of that area of the vehicle was pretty unchanged from day one.
With David's advice ringing in my ears i dutifully placed all the panels as per his drawings
With David's advice ringing in my ears i dutifully placed all the panels as per his drawings
The halfround strip was received, and using this and thin sheet a set of ECS radiators was constructed
The halfround strip was received, and using this and thin sheet a set of ECS radiators was constructed
The finished set prior to painting
The finished set prior to painting
The small stiffening detal added and holes drilled
The small stiffening detal added and holes drilled
The complete set of radiators painted and ready to go. The small ones to the left are resin ones that were part of the New Ware detail set
The complete set of radiators painted and ready to go. The small ones to the left are resin ones that were part of the New Ware detail set
The RCS thruster quads are 3d Printed items from Vincent Meens, they are superb, and are exquisitely detailed. As mentioned before i placed a locating hole in the RCS door panel so that they could be lined up. In the photo above they are placed in a jig that holds them in place, and lifts them so they can be placed upside down without snapping off the delicate nozzles. A hole is drilled in the centre for a peg
The RCS thruster quads are 3d Printed items from Vincent Meens, they are superb, and are exquisitely detailed. As mentioned before i placed a locating hole in the RCS door panel so that they could be lined up. In the photo above they are placed in a jig that holds them in place, and lifts them so they can be placed upside down without snapping off the delicate nozzles. A hole is drilled in the centre for a peg
A small dowel peg is glued into place. now the quads are just pressed into place on the model, with no need of any glue
A small dowel peg is glued into place. now the quads are just pressed into place on the model, with no need of any glue
There is a small electrical junction box sited on the rear of the SM. This box is supplied as part of the New Ware detail set. Here it is being folded into shape
There is a small electrical junction box sited on the rear of the SM. This box is supplied as part of the New Ware detail set. Here it is being folded into shape
The finished box
The finished box
A reference photo of the rear end of the service module showing the yellow coloured section of the heat shield. It can be seen as a distinctly separate piece
A reference photo of the rear end of the service module showing the yellow coloured section of the heat shield. It can be seen as a distinctly separate piece
To depict that yellow section on the heatshield would have meant an extremely tricky masking and painting exercise. So i went with the idea of making a separate piece that could be painted and installed later on
To depict that yellow section on the heatshield would have meant an extremely tricky masking and painting exercise. So i went with the idea of making a separate piece that could be painted and installed later on
Working out the pattern using an online calculator
Working out the pattern using an online calculator
It is a very delicate item made from 0.12mm -0.005" thick sheet
It is a very delicate item made from 0.12mm -0.005" thick sheet
The rib layout scribed onto paper
The rib layout scribed onto paper
thin half round strips used to replicate the ribs
thin half round strips used to replicate the ribs
Another random shot of the workbench in one of its saner moments
Another random shot of the workbench in one of its saner moments
The finished items. As with a fair few items that i build it is a push fit and does not require gluing.
The finished items. As with a fair few items that i build it is a push fit and does not require gluing.
One tool that i have deserves a mention. This is the DSPIAE circle cutter. You adjust the cutter to the size circle you require by moving the cutting head using the printed scale on it a your guide. Place it on the sheet you are using, and the black section is rotated around with the handle, and the cutter cuts . It can cut circles between 1 to 50 mm diameter, it is suitable for cutting paper, masking tape, and really thin styrene. It will also score thicker styrene enough that it will give a good cutting guide. When i received it i was impressed right from the word go as it looks and feels like a high quality piece of kit
One tool that i have deserves a mention. This is the DSPIAE circle cutter. You adjust the cutter to the size circle you require by moving the cutting head using the printed scale on it a your guide. Place it on the sheet you are using, and the black section is rotated around with the handle, and the cutter cuts . It can cut circles between 1 to 50 mm diameter, it is suitable for cutting paper, masking tape, and really thin styrene. It will also score thicker styrene enough that it will give a good cutting guide. When i received it i was impressed right from the word go as it looks and feels like a high quality piece of kit
The engine bell was painted. The colours i ended up using was again the result of a lot of research, and looking at other peoples models. Eventually i ended up trying to match them as closely as possible to how it appeared in flight photographs
The engine bell was painted. The colours i ended up using was again the result of a lot of research, and looking at other peoples models. Eventually i ended up trying to match them as closely as possible to how it appeared in flight photographs
Colours used for the heat shield and engine bell
Colours used for the heat shield and engine bell
The white circle on the service module umbilical panel was cut from using the cutter. This small panel was one that i noticed on reference photos late on in the build. This can be seen as the SM is in prime paint, and here it was ready for top coat. I have spent many many hours looking at the set of photos i have, and it seems that every time i revisit a photo i notice something new
The white circle on the service module umbilical panel was cut from using the cutter. This small panel was one that i noticed on reference photos late on in the build. This can be seen as the SM is in prime paint, and here it was ready for top coat. I have spent many many hours looking at the set of photos i have, and it seems that every time i revisit a photo i notice something new
This is a great reference photo that shows the Hi Gain Antenna assembly. This could swivel and rotate to lock the signal on to the ground tracking dishes
This is a great reference photo that shows the Hi Gain Antenna assembly. This could swivel and rotate to lock the signal on to the ground tracking dishes
The Kit version is not the best, an enhancement is supplied with the New ware kit, this relies upon cutting up the kit version and adding some resin sections, and using photo etch parts for the dishes. Micheal Key sells a 3D printed version, I used his body and the mesh dishes from the New ware set
The Kit version is not the best, an enhancement is supplied with the New ware kit, this relies upon cutting up the kit version and adding some resin sections, and using photo etch parts for the dishes. Micheal Key sells a 3D printed version, I used his body and the mesh dishes from the New ware set
The 3d printed dishes supplied with the frame are shown here alongside the photoetched versions from New Ware. I decided to use the frame from Micheal, and the new ware dishes
The 3d printed dishes supplied with the frame are shown here alongside the photoetched versions from New Ware. I decided to use the frame from Micheal, and the new ware dishes
The circle cutter was used to make a template
The circle cutter was used to make a template
The template was used to ensure that the holes drilled in the dishes and spiders were centred
The template was used to ensure that the holes drilled in the dishes and spiders were centred
The spiders and mesh frames cut from the sheet
The spiders and mesh frames cut from the sheet
In this shot you can see the silver coloured dished that came with the kit
In this shot you can see the silver coloured dished that came with the kit
I read descriptions of how other builders had formed the dishes, and had a go with the two spoon method. This works fine, but i didn't have any spoons in the house that were curved enough to give the required depth
I read descriptions of how other builders had formed the dishes, and had a go with the two spoon method. This works fine, but i didn't have any spoons in the house that were curved enough to give the required depth
After rooting about the house i found the cap from a roll on deodorant bottle was just what i was looking for
After rooting about the house i found the cap from a roll on deodorant bottle was just what i was looking for
This was then used as the female half of a die to form the dishes in. The rounded end of a paintbrush was used to push them in
This was then used as the female half of a die to form the dishes in. The rounded end of a paintbrush was used to push them in
The completed dishes with the spiders glued into place
The completed dishes with the spiders glued into place
The main frame was modified with some small round discs, and locating pins inserted into 0.6mm holes drilled into the arms. The locators were cut from an embroidery needle
The main frame was modified with some small round discs, and locating pins inserted into 0.6mm holes drilled into the arms. The locators were cut from an embroidery needle
The dishes were pinned to a strip of styrene ready for painting
The dishes were pinned to a strip of styrene ready for painting
The RCS pods were prepped as well
The RCS pods were prepped as well
At first i was going to use the feed horns from the 3d dishes, but after snapping them, and trying to make a repair i ditched them and went for some scratchbuilt ones. These were made from Aluminium tube, brass tube and styrene discs
At first i was going to use the feed horns from the 3d dishes, but after snapping them, and trying to make a repair i ditched them and went for some scratchbuilt ones. These were made from Aluminium tube, brass tube and styrene discs
The main frame and support arms on the real craft are covered with white cloth insulation. The model part is covered with paper to simulate this. I used thin tissue soaked in a water and flour mixture. It took me back to childhood memories of making paper mache models at school. When it was totally covered it had a coat of clear modelling varnish applied, this allowed it to be sanded down. When the desired finish was obtained it was painted white
The main frame and support arms on the real craft are covered with white cloth insulation. The model part is covered with paper to simulate this. I used thin tissue soaked in a water and flour mixture. It took me back to childhood memories of making paper mache models at school. When it was totally covered it had a coat of clear modelling varnish applied, this allowed it to be sanded down. When the desired finish was obtained it was painted white
The dishes being assembled to the frame. The dishes slipped over the locating pins and the small whit discs were a firm push fit over the pins, securing the dishes with no glue required.
The dishes being assembled to the frame. The dishes slipped over the locating pins and the small whit discs were a firm push fit over the pins, securing the dishes with no glue required.
A veiw from the rear
A veiw from the rear
The finished article. I was feeling quite chuffed with the effect, that was until the next day when i looked at some more reference photos and noticed that on the real thing the feed horns are not actually in the centre of the dishes. They are offset, the base is not on the centre and lean inwards so that the tip is on the centre line. Again allthough not historically a 100% they are close enough, and have a good enough finish for me to accept
The finished article. I was feeling quite chuffed with the effect, that was until the next day when i looked at some more reference photos and noticed that on the real thing the feed horns are not actually in the centre of the dishes. They are offset, the base is not on the centre and lean inwards so that the tip is on the centre line. Again allthough not historically a 100% they are close enough, and have a good enough finish for me to accept
The SM in my expensive (Amazon cardboard Box) Spraybooth
The SM in my expensive (Amazon cardboard Box) Spraybooth
The final topcoat is applied. All that is left to do is to paint the white panel on sector two, apply the decals and attach the radiators
The final topcoat is applied. All that is left to do is to paint the white panel on sector two, apply the decals and attach the radiators
The area for the white panel masked
The area for the white panel masked
Painted
Painted
Masking removed
Masking removed
The masking was also removed from the running lights, small lenses were glued in place, and another check carried out to ensure all lights were still working
The masking was also removed from the running lights, small lenses were glued in place, and another check carried out to ensure all lights were still working
Then it was time to apply decals. The set used were produced by Rick Sternbach. He supplies a roadmap of decal positions, and the set contains all decals to cover the 11 flights that the module made, so not all are relevant for each flight. The supplied roadmap shows the placement for each mission, i took this and modified it just to reflect the Apollo 9 mission, this is shown above
Then it was time to apply decals. The set used were produced by Rick Sternbach. He supplies a roadmap of decal positions, and the set contains all decals to cover the 11 flights that the module made, so not all are relevant for each flight. The supplied roadmap shows the placement for each mission, i took this and modified it just to reflect the Apollo 9 mission, this is shown above
Each decal has the index number printed nearby it, this is a nice touch as it saves any confusion
Each decal has the index number printed nearby it, this is a nice touch as it saves any confusion
During the decal application i decided to also glue the ECS radiators into place. I did make life difficult for myself as i did not preform them enough prior to painting, and it was not the easiest of jobs to line them up and glue them down
During the decal application i decided to also glue the ECS radiators into place. I did make life difficult for myself as i did not preform them enough prior to painting, and it was not the easiest of jobs to line them up and glue them down
The first pair successfully applied, this was tricky as i didn't want any glue to get pushed out from under them and stain the paint finish on the module, but needed them to be glued as closely as possible.
The first pair successfully applied, this was tricky as i didn't want any glue to get pushed out from under them and stain the paint finish on the module, but needed them to be glued as closely as possible.
The the smaller EPS radiators were attached. In all cases i used gorilla glue, the Gel type. It dose not run as it is a gel, and also gives you a few seconds to finely align what you are gluing as it does not grab straight away
The the smaller EPS radiators were attached. In all cases i used gorilla glue, the Gel type. It dose not run as it is a gel, and also gives you a few seconds to finely align what you are gluing as it does not grab straight away
All radiators in place
All radiators in place
Decals applied to thruster quads
Decals applied to thruster quads
The rendezvous light had a lens applied
The rendezvous light had a lens applied
A still shot from a video, this light is a flashing light
A still shot from a video, this light is a flashing light
the module was upended and placed in the jig for further work
the module was upended and placed in the jig for further work
The heatshield has two fuelling ports. Rather than trying to paint the tiny details i took a screngrab of the real thing, shrunk it down to scale in Inkscape, then printed it and cut out the circular section
The heatshield has two fuelling ports. Rather than trying to paint the tiny details i took a screngrab of the real thing, shrunk it down to scale in Inkscape, then printed it and cut out the circular section
These were then inserted into the port
These were then inserted into the port
There is a bundle of wiring that was used to connect the module to the spacecraft, and then to a ground supply when the vehicle was on the pad. Some wiring brackets were made. Unused wire from some LEDS was used
There is a bundle of wiring that was used to connect the module to the spacecraft, and then to a ground supply when the vehicle was on the pad. Some wiring brackets were made. Unused wire from some LEDS was used
The wires were inserted into a holder that was placed in the body
The wires were inserted into a holder that was placed in the body
The housing was glued into place, and the brackets positioned
The housing was glued into place, and the brackets positioned
Small connector blocks slid over the wires
Small connector blocks slid over the wires
The excess wire trimmed off. At this stage the module was ready for the final assembly stage
The excess wire trimmed off. At this stage the module was ready for the final assembly stage
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