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Integrate Piston Cup Assembly

Rule: if you are not directly helping with integration, you must be dancing.

Pre-Assembly: Build the Firebolt Jumbo

FILL THIS OUT

Primary Integration Checklist

  1. Make sure that the PISTON rod is fully compressed (retracted).
  2. Integrate the 1/8TH NPT ELBOW FITTING into the piston inlet port that is closest to the blunt end. Use approximately three wraps of TEFLON TAPE. Make sure that the male end of the elbow fitting is pointing downwards.
  3. Screw in the Jumbo Firebolt into the male end of the elbow fitting using approximately three wraps of Teflon tape

  4. Screw the PAYLOAD BULKHEAD into the top of the piston using four LENGTH HERE 1/4-28 BOLTS. You need a 3/16THS HEX KEY.

  5. INSERT AVIONICS BAY INTEGRATION PROCEDURE HERE

  6. Put the AVIONICS BAY COUPLER over the piston. The coupler's switchband should be closer to the side with the Firebolt screwed in.

  7. Using four LENGTH HERE 1/4-28SCREWS screw in the AVIONICS BULKHEAD to the bottom of the piston. The milled face (mass saving cuts) should be internal to the Avionics Bay. Use the 3/16ths hex key again. 

  8. Fully screw a 3/8-16TH NUT onto the piston. Slide the DIAPHRAGM onto the piston and screw in the 3/8-16TH EYE BOLT.
  9. INSERT INFORMATION ON USING LOCTITE
  10. Put the COTTER PIN in the eye nut. 
  11. Put a 1000LB QUICKLINK on the eye nut. Don't close the quicklink yet.
  12. Now it's time to integrate the two TENDER DESCENDERS. Prepare yourself emotionally for this experience.
  13. Attach both Tender Descenders using one of the two KEVLAR LOOPS to the quicklink. The Tender Descenders should be in parallel. Consult this page for more information.
  14. Congrats! You've finished integrating the Tender Descenders.
  15. Screw the diaphragm into the CUP with FOUR 10-32 GRUB SCREWS using a 7/64 HEX WRENCH.

 

  1. (Stand in step for CRIMP) Tie a piece of paracord to the eye nut. Tie a knot on the other end.
    1. NOTE ON HARDWARE REV: If the new eye nut is too large to put a quicklink around, consider milling the eye nut down, sewing a piece of webbing onto it, or otherwise just doing something more professional than "tie a piece of paracord." 
    2. Secure a 1000lb quicklink to the paracord, followed by a 1500lb swivel and another quicklink.
      1. PROPOSED CHANGE FOR HARDWARE REV: See if you can't sew at least one line directly onto the swivel?
      2. POTENTIAL CHANGE: Perhaps everything should have its own swivel?
  2. Coil the booster–mission package webbing and stow in several small infinity wraps using minimal tape. The optimal height of the infinity wrap is a little over 1". Leave enough slack (i.e. do not infinity wrap) on one side to extend the lines from the diaphragm to the forward closure.
  3. Attach the booster-mission package webbing to the at the diaphragm quicklink.
  4. Attach both Tender Descenders in series to the quicklink attachment point. Attach the drogue riser onto the second Tender Descender quicklink. For the time being, leave the line on the outside of the cup.
     
  5. Coil the main riser and stow in several small infinity wraps using minimal tape.
  6. Attach one end of the main riser onto the quicklink attachment point. Attach the other end to the packed main parachute.
    1. Pack the coiled riser behind the main parachute (towards the nose cone) inside of the cup. 
    2. PROPOSED CHANGE: Add a section on packing the main parachute before this.
     

  7. Put the airframe tube over the assembly. You may need to move the drogue riser and mission package to booster webbing out of the way.

    1. “Struggle with clocking” - Jakob, 11:20am

  8. Screw in four ½” 8-32 screws to attach the airframe to the Avionics Bay.
  9. Attach the drogue riser to the packed drogue with a 220 lb quicklink. Coil and stow excess drogue line (if necessary) and pack everything into the booster section.
  10. Coil and stow excess mission package to booster webbing and secure with a small amount of painters tape. Place this in the booster section. Then attach the mission package to booster webbing to the forward closure with a 1000lb quicklink, followed by a 1500lb swivel, and then another 1000lb quicklink.
    1. PROPOSED CHANGE FOR HARDWARE REV: See if you can sew it onto the swivel.
  11. Now, attach the other side of the mission package to booster webbing to the forward closure

  12. Screw in the nosecone with the right clocking using four 8-32 screws.

  13. Put the mission package assembly on the booster and secure with 3x 6-32 shear pins. For the Pathfinder vehicle, you will need to skip every other hole.

Notes from integration:

  • Purchase 6x 8-32 grub screws 

Materials:

Diaphragm

Piston (small)

1/8th NPT elbow fitting

Teflon tape

7/64 hex wrench

Payload bulkhead

Four LENGTH HERE 1/4-28 bolts

3/16THS Hex key

Avionics Bay Coupler

LENGTH HERE 1/4-28 screws

3/8-6TH nut

3/8-16TH eye bolt

Loctite

Cotter pin

 

Cup

 

Four 10-32 grub screws



plug

FireBolt XL

Avionics Bay (Coupler)

eye nut

cotter pin

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