CONSTRUCTION OF THOR
Here are pictures with explanations of the steps taken in building THOR.
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This is the first step in construction- the fins. The booster fins are an overdosing by using 1/2 thick carbon fiber plate. This is because the first rocket that flew to 90,000 feet had 1/2" fins and deviating from a successful design didn't seem logical. The fins were placed in a "fin jig" that is lined up perfect. Then three layers of 4.5 OZ carbon fiber cloth is applied at the 3 joints.
Becky Green working on the first set of fins in a wonderful shop- courtesy of our friend- John Coker.
Once the fins are bonded to each other the next step is to add the three rocket motor tubes. These also act as a main structural element and are where the rocket motors slide into.
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All tubes, bulkheads and fins are ready for more strengthening by bonding the tubes to the fins.
This is the bonding step by applying high strength epoxy to the tubes, bulkhead plates, and fins for creating a monolithically built rocket .
View from the rear with the three motor tubes, rear bulkhead plate and the exterior airframe in place ready for the carbon fiber cloth wrap.
Machining the Delrin sleeve. This sleeve slides into the Interstage coupler so the second stage rocket slides out easily.
This is the low friction Delrin sleeve ready to be installed inside the aluminum collar that is the structural strength for supporting the Delrin.
The Delrin and aluminum sleeves mounted in the interstage's bulkhead plate.
These are 1/2" carbon plates cut to fit into the interstage, to join the entire structure together.
Interstage ready for the application of the carbon fiber at the top.
Front view of interstage showing the lower bulkhead plate and the recessed area the second stage motor nests into. The perimeter holes are drilled to lighten the assembly.
These are the 3D printed pieces that support the 4 layers of 4.5 oz carbon fiber cloth that will be applied around the tapered section.
The finished interstage coupler.
