Copyright 2009 John Jogerst. Not for commercial use. For personal or educational use only.

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Edgar Davis
6 years ago
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1 ISS 4.5 1:40 scale Building this model requires a moderate level of modeling skill and an intimate familiarity with the International Space Station structure see Model is approximately 1:40 scale; sized to use 2 liter soda bottles to shape the modules. The finished model will be 6 feet high across the main solar arrays, just over 8 feet wide across the main truss, and about five feet long along the main spine where the modules mount. Most sections consist of a cylinder using a bottle as a form and two end caps. More complex shapes are formed from cones and boxes. Sections are assembled with 1 ¼ inch PVC tubing running though the part and connectors where needed. Most conics are formed by cutting on the solid radial lines, then forming and overlapping to the dotted line. Non-structural connections are made with either a paper tube rolled to the same outside diameter as the tubing (1.68 inch/43mm) or with slip-fit cylinders. These connections include the cupola, airlock, JEM small experiment module, the PIRS docking compartment and Soyuz spacecraft. To make a slip-fit docking connection, first close the open ends of the modules to be joined with a circular piece of card. Using a mandrel (cylindrical form), roll and glue a cylinder at least 1 inch long from card stock. When dry, roll a second cylinder over the first, wrapping tightly. When gluing the second cylinder, make sure you don t glue it to the first (inner) piece. Cut a ½ inch (1 cm) section from both cylinders and glue one piece to each of the parts to be joined. When dry, the two cylinders should slip over each other for a friction fit. Secure with glue for a permanent display. The truss is assembled from hexagonal and rectangular box sections. Each section is capped and that end cap has a hole to allow the 1 ¼ inch PVC support tubing to pass through. The tubing runs off-center to accommodate the shape of the S1 and P1 truss sections. The main solar arrays are made from plain paper segments (to save weight) supported by a 3/16 inch dowel glued up the center of each array. The arrays are mounted to the truss using a 7/32 inch brass tube secured in a hole drilled through the main truss PVC support tube. The solar array dowels then slip into the tubing. The radiators for the solar arrays are suspended from a dowel attached to the main truss and attached to the outer end of the radiator. The main thermal radiators are suspended from a stiff wire that runs up the center of the mount, then bends 90 degrees and extends out to connect with the end of the top radiator panel. All three panels are tied together at the outer end with a strip of card to hold them up. The finished model should be suspended from (or supported at) at least four points: both ends of the truss, the center of the truss, and the back end (Progress/Zvezda) of the central spine. Copyright 2009 John Jogerst. Not for commercial use. For personal or educational use only.

2 STRUCTURAL SUPPORT CEILING HANGER DISPLAY Vertical connection must be glued 5 feet EYE BOLT ADDITIONAL STRUCTURE (NODE, LS MODULES, CREW VEHICLES) ATTACHED WITH GLUED PAPER TUBING: NON-STRUCTURAL 1 ¼ INCH PVC JEMM PALLET EYE BOLT 36 inches ZVEDZA SOYUZ ATV ETC. ZARYA Z1 TRUSS NODE ADDITIONAL NODE LATER MAIN TRUSS DESTINY JEMM COLUMBUS inches EYE BOLT PROGRESS ZVEDZA ZARYA NODE DESTINY 6.5 inches 13.5 inches JEMM NODE COLUMBUS SOLAR ARRAY SUPPORT 3/16 dowel RADIATOR SUPPORT WIRE BENT INTO BASE. 8 feet TRUSS SUPPORT RADIATOR EYE BOLT Z1 TRUSS EYE BOLT 1 ¼ INCH PVC SOLAR ARRAY SUPPORT 7/32 4 brass tubing Drill 7/32 hole through main tube and epoxy brass tube in place. Slip fit dowel into brass tube. EYE BOLT inches 6 feet 36 inches

4 Modules PVC SUPPORT TUBE END CAP END CAP CYLINDER

5 NODE

6 NODE END CAPS HATCHES R. Fortezza -1999

7 R. Fortezza -1999

8 NODE docking adapter R. Fortezza -1999

9 NODE cupola R. Fortezza NODE - AIRLOCK SIDE BANDS FOR CYLINDER END BARREL LARGE CAPS

10 NODE airlock END BARREL LARGE CAPS

11 NODE airlock SIDE BAND GAS CANNISTERS (4)

12 PIRS DOCKING COMPARTMENT

13 FGB/UDM Zarya (use radiator array) Research Module AFT TRANSITION CONES NARROW EQUIPMENT CABINETS WIDE EQUIPMENT CABINETS (RM has two solar arrays set at 90 degree angle, no radiator, only aft set of narrow equipment boxes) BODY CYLINDER CONNECTOR/DOCK SERVICE MODULE Zvezda Multipurpose Lab Module CONIC FORMER MID-BODY TRANSITION SEE NASA WEB SITE FOR DETAILS ON POSITIONING OF EQUIPMENT BOXES, RADIATOR, AND SOLAR PANELS. Cut out circular opening to attach docked spacecraft or modules. Use slip-fit cylinders to form attachments. AFT CAP AFT CYLINDER FWD CYLINDER CONNECTOR/DOCK Detailed airlock if used. Use on second set of modules mounted below station, not on main spine. If used on spine modules, enlarge end cap hole to fit armature.

14 FGB/UDM AFT TRANSITION CONES END CONE

15 FGB/UDM BODY CYLINDER

16 FGB/UDM CONNECTOR/DOCK

17 FGB/UDM CONIC FORMER CUT OUT CENTER FOR ARMATURE FOLD TABS IN ALTERNATE DIRECTIONS TO CONNECT TO CONES (2) FORE AND AFT OF THE FORMER. RUN U-SHAPED COAT HANGER WIRE FOR SUPPORT. BEND UP INNER ENDS TO HOLD ALIGNMENT. TOP VIEW SIDE VIEW RADIATOR PANELS NEXT PAGE Two panels, cut long center line, fold on short verticals, pierce dots for support wire.

18 FGB/UDM

19 RESEARCH MODULE VARIANT SOLAR ARRAYS

20 RESEARCH MODULE VARIANT SOLAR ARRAYS

21 FGB/UDM EQUIPMENT CABINETS

22 FGB/UDM EQUIPMENT CABINETS

23 FGB/UDM EQUIPMENT CABINETS

24 DETAILED AIRLOCK SECTION FOR FGB/UDM OR SM

25 DETAILED AIRLOCK SECTION FOR FGB/UDM OR SM ROLL SLIP CYLINDERS (see page 1) CUT APART ALONG LINES AFTER ROLLING BODY CYLINDER END CAP

26 SERVICE MODULE PRINT ON PLAIN PAPER INNER SOLAR PANEL INSERT COATHANGER WIRE FOR SUPPORT. RUN FULL LENGTH OF INNER AND OUTER PANELS. FOLD AND GLUE. INSERT TABS BETWEEN LAYERS OF OUTER PANELS.

27 SERVICE MODULE PRINT ON PLAIN PAPER INNER SOLAR PANEL

28 SERVICE MODULE PRINT ON PLAIN PAPER OUTER SOLAR PANEL

29 SERVICE MODULE PRINT ON PLAIN PAPER OUTER SOLAR PANEL

30 SERVICE MODULE AFT CYLINDER

31 SERVICE MODULE MID-BODY TRANSITION AFT

32 SERVICE MODULE FORWARD CYLINDER

33 SERVICE MODULE CONNECTOR/DOCK

34 DESTINY LAB

35 DESTINY LAB Destiny

36 DESTINY LAB END CAPS

37 COLUMBUS LAB Columbus lab is also logistics module, typically dismounted after loading/ unloading and lands with Shuttle.

38 COLUMBUS LAB Columbus

39 COLUMBUS LAB END CAPS

40 JEM LAB

41 JEM LAB

42 JEM LAB END CAPS

43 JEM EXPOSURE FACILITY PALLET

44 JEM EXPOSURE FACILITY PALLET EQUIPMENT BOXES

45 JEM EXPOSURE FACILITY EQUIPMENT BOXES

46 JEM ELM

47 JEM ELM END CAPS

48 LIFE SUPPORT MODULE (future) END CONES BODY CYLINDER

49 RESEARCH MODULE DOCKING/STORAGE MODULE (future) END CAP FOR CONIC IF NEEDED COVER WITH HATCH IF EXPOSED END CONES OPTIONAL FLAT END CAP

50 RESEARCH MODULE, DOCKING/STORAGE MODULE (future) BODY CYLINDER

51 MOBILE TRANSPORTER/BASE BOX BOX BOTTOM TO TRUSS

52 MOBILE TRANSPORTER/BASE MOUNTING PLATFORM GLUE TO BOX, THEN ATTACH TO TRUSS ROBOT (CANADARM) ARM END FITTINGS BOX MOUNT ON BOX BOTTOM Flexible straws sleeved together sections about 7 inches long. Cover with white tape or paint.

53 CANADARM DEXTRE 3 JOINTS 1 ARM SECTIONS ROLL

54 Z1 TRUSS - enlarged TRUSS SIDE BOTTOM

55 Z1 TRUSS -enlarged TOP BACK AWAY FROM TRUSS TO TRUSS

56 Z1 TRUSS enlarged SIDES

57 Z1 TRUSS enlarged S0 TRUSS

58 S0 S1 S 3-4 inner TRUSS ALIGNMENT S 3-4 i S 3-4 outer/s 5-6

59 S0 TRUSS JEMM SIDE

60 S0 TRUSS JEMM SIDE

61 S0 TRUSS TOP TOP

62 S0 TRUSS TOP TOP

63 S1/P1 TRUSS INNER

64 S1/P1 TRUSS INNER

65 S1/P1 TRUSS INNER TOP BACK

66 S1/P1 TRUSS INNER TOP BACK

67 S1/P1 TRUSS OUTER

68 S1/P1 TRUSS OUTER

69 S1/P1 TRUSS OUTER TOP BACK

70 S1/P1 TRUSS OUTER TOP BACK

71 S/P 3-4 TRUSS INNER TOP

72 S/P 3-4 TRUSS INNER TOP

73 S/P 3-4 TRUSS INNER TOP TOP

74 S/P 3-4 TRUSS INNER TOP

75 S/P 3-4 TRUSS OUTER OUTBOARD

76 S/P 3-4 TRUSS OUTER OUTBOARD

77 S/P 3-4 TRUSS OUTER OUTBOARD

78 S/P 3-4 TRUSS OUTER OUTBOARD

79 S/P 3-4 TRUSS OUTER

80 S/P 5-6 TRUSS INNER OUTBOARD

81 S/P 5-6 TRUSS INNER OUTBOARD

82 S/P 5-6 TRUSS INNER OUTBOARD

83 S/P 5-6 TRUSS INNER OUTBOARD

84 S/P 5-6 TRUSS OUTER OUTBOARD

85 S/P 5-6 TRUSS OUTER OUTBOARD

86 S/P 5-6 TRUSS OUTER OUTBOARD

87 S/P 5-6 TRUSS OUTER OUTBOARD

88 S/P 5-6 TRUSS END CAPS OUTER CAPS

89 S/P 5-6 TRUSS END CAPS OUTER CAPS

90 MAIN SOLAR PANELS PHOTO-VOLTAIC ARRAY (PVA) GOLD SIDE VIEW Mounting rod 36 plus length to insert into truss. Glue up reinforcing beams from card stock rectangle sized to match width of solar array. Beam profile about ½ wide. Glue reinforcing beams at ends to gold side; cut hole to run mounting rod through bottom beam; butt-glue rod to top beam to support array

91 SOLAR PANEL FRONT; ONE OF SIX PER ARRAY; EIGHT ARRAYS TOTAL. (48 PAGES) PRINT ON PLAIN PAPER back to back with next page, use gold side to guide cutting.

92 SOLAR PANEL BACK; ONE OF SIX PER ARRAY (48 PAGES) PRINT ON PLAIN PAPER cut out panel from this side. Use overlap on bottom edge to connect to next segment

93 SOLAR PANEL FRONT; ONE OF SIX PER ARRAY; EIGHT ARRAYS TOTAL. (48 PAGES) PRINT ON PLAIN PAPER back to back with next page, use gold side to guide cutting. ALTERNATE PRINT ON BLUE PAPER; GLUE NEXT PAGE ON BACK

94 SOLAR PANEL BACK; ONE OF SIX PER ARRAY (48 PAGES) PRINT ON PLAIN PAPER cut out panel from this side. ALTERNATE PRINT ON YELLOW/GOLD PAPER Use overlap on bottom edge to connect to next segment

95 SOLAR PANEL RADIATOR. ONE OF FOUR; ONE PER ARRAY AXLE. TRUSS 4&6. TUBE TRUSS ADD TO SUPPORT AND CONNECT ATTACH TO BACK SIDE OF TRUSS OVERLAP TO CONNECT

96 THERMAL RADIATOR. EIGHT SECTIONS PER STRING; THREE STRINGS PER TRUSS; MOUNT ON TRUSS 1. (print page 12 times total) PRINT ON PLAIN PAPER CONNECTOR CONNECTOR

97 THERMAL RADIATOR HALF MOUNT. FOUR PARTS TOTAL TO MAKE TWO MOUNTINGS. TRUSS 1 MOUNT. Overlap connection to second part of mount. ADD STRIP AT END TO CONNECT ALL 3 RADIATORS AND WRAP END OF WIRE FOR SUPPORT STIFF WIRE TRUSS MOUNT This part will need a support use stiff wire to hang radiators. Base of each radiator set attaches to mount. Mount attaches to truss (see NASA website for detail).

98 PROGRESS AFT AFT BODY CYLINDER AFT CONIC FWD CONIC BODY CYLINDER SOYUZ FWD CONICS FWD CYLINDER BODY CONIC BODY CYLINDER AFT CONIC AFT

99 PROGRESS FWD CONIC PROGRESS ARRAYS SOYUZ ARRAY

100 PROGRESS AFT CONICS FOR PROGRESS AND SOYUZ (1 EACH) AFT SOYUZ SOYUZ

101 SOYUZ FWD CYLINDER BODY CONIC (USE 1)

102 SOYUZ BODY CYLINDER FWD CONICS (2)

103 PARTS

Solar Probe Plus Approx 1:40 scale

Solar Probe Plus Approx 1:40 scale Solar Probe Plus Approx 1:40 scale Sunshield bottom Sunshield top For personal/educational use only. sunshield Sunshield edge Align shade with secondary solar array Secondary