Hermes 2 Payload Bulkhead

Overview:

The purpose of the payload bulkhead is to connect the mission package tube (with the avionics tower within) to the nose cone, each of which have a 6" outer diameter. The payload bulkhead is divided into two parts: the payload tube and the payload plate. The payload tube has two sections but is one part, made from the same tube stock: the mission package section, and the nose cone section. Below is a table showing the dimensions of the mission package tube and the nose cone, which affect the dimensions of each section of the payload tube. The payload plate is a round aluminum disk attached to the tube via bolts. It has a square indent on the mission package side, into which one end of the piston fits, and holes to attach the "payload stack" (a tiered assembly supporting the data acquisition, video downlink system, and other necessary items) that is located in the nose cone. 

The original plan was to bore out the entire payload bulkhead out of a single piece of aluminum stock, but this would both be a waste of material and technically challenging, as the thickness of the bulkhead is 1/8" (0.125"). Therefore, the bulkhead, as described earlier, will be made out of two pieces: a thin disk attached to a tube via bolts.