posted 11-13-2007 11:38 PM               

The command module here will be reproduced in fiber-glass and those new parts will be detailled and scribed and will become the final master parts. I will then make a silicone molds to make the final parts in resin.

Here you can also see the solar panel master part in progress and the panel arms. The final solar panel. This is also not the final part, I will make a special mold from which vacuum forme plastic sheet will molded to make thin solar panel components without need for photo-etched parts.

The model features the latest up to date avionics ring with curved side-walls (unlike the flat-panelled sidewall of the earlier 606 CEV version), the model does include as well the longer service module rear section, larger solar panels, and a wide variety of other changes that were not included in earlier models, such as different position of RCS engines on the command module, different panel lines and details on command module, no "mylar" foil on the service module, etc. The service module will also feature radiators. But of course, anyone who wishes can still put gold mylar on that part to add a touch of color to the model (I plan to try that myself).

The parts you see here are fiberglass (and have been polished smooth like glass)(I will polish it even further when the final masters for the command module are ready).

posted 11-21-2007 07:36 PM               

Here I glued and completed the master for the solar panels:

Here's the fiberglass molds for the command module cone shape and the heat shield (which I nicknamed: fiberglass omelet and flan pudding). Don't be scared, it will look much better in a moment.

Much better looking that the previous pictures. There are a few nicks and scratches inside, typical of that type of mold after demolding the masters (I found there was a slight overhang on the heat shield, so I had to struggle to get it out of the mold, but that one, I saved it in one piece (unlike the cone shape).

The small scratches and couple of small air bubbles will be easily repaired and polished, then I will make the fiberglass copies that will be used as the final master parts and detailed and scribed.

posted 12-17-2007 03:58 AM               

It was faster than expected and in fact it would have been even faster if it had not been for me being very busy three weeks earlier with an urgent matter which is now completed.

I am now free to devote more time to the CEV and other kits.

I am designing the kit in a totally modular fashion so that it will be easy to update if ever they do change some elements and make a 608 version.

posted 12-28-2007 05:00 PM               

I found out a new document, all fresh from late November with a lot of new information, and it turns out that what I was modeling so far was the Orion CEV 606-A. There has been some little changes and the model is now made officially to the Orion 606-C standard.

Based on what I have read about the project's schedule and previous NASA meetings, I do not expect any other changes (at least nothing bigger than changing panel lines or small details) for the CEV command module itself.

We are now down to groups of two engines for the CEV command module (from previous groups of four engines for the 606 version, to groups of three maneuvering engines for the 606-A, to now groups of two for CEV 606-C). It cannot go lower than that, because NASA has a requirement for redundancy for critical systems. So at least, for the maneuvering engines it is fixed.

For the service module, there are some relatively important changes but they were easy to add to the model since it is built in a modular fashion. The changes concern the number of maneuvering engines and auxiliary engines. We go to groups of four and two engines.

They have now added what looks like composite radiator panels on the SM (as hinted in the document I have found).

Here is the almost complete high gain antenna:

The new Orion CEV 606-C version, we're almost there!

The photo shows the four new panels on the service module. The auxiliary engines will now be off center and mounted on the 4 wedge shapes on the circumference of the rear fuselage.

I am now working at completing the small details and I am already working on the base. I will soon reduce the number of RCS engines on the CM to bring it to 606-C standard.

I will start to make the first molds as soon as I receive the first orders that are underway, for this early January.

posted 01-12-2008 05:49 PM               

The Bondo flange inside the avionics ring was not there originally when I turned the part. I will detail how I added it as well as the concave bulkhead for the fuel tanks later on, this was quite simple but required a series of little special tools I made to create these.

This is the avionics ring after modification. I totally removed the floor of the ring and replaced it with a new bulkhead with holes through which the top of the fuel and oxidizer tanks are visible. More details will be added. The dome shapes that you see do not represent the final size of the tanks.

The white components represent the final diameter of the top of the fuel tanks. The ochre parts are just there to show what the final arrangement will like with the domes installed.

posted 01-16-2008 07:14 PM               

I started manufacturing the first parts for the CEV Orion kit last night. The result is very good as the parts are inherently stable and rigid due to the corrugations of the panels (they will not deform, unlike a flat solar panel made of the same material or from resin). The material is quite thin, so it replicates quite well the appearance of actual solar panels, and it is lightweight, which is a good thing, since the attachment points for the solar panel arms will be very thin (I will use piano wire inserts inside the castings for each of those attachment parts).

posted 01-23-2008 09:37 PM               

I will also most likely add a bevel to the side of the base. I am now going to smooth finish the masts and attach everything and make the assembly points.

posted 02-04-2008 02:49 AM               

The most expensive items in the tool in question were the two laboratory clamps that I had to pay more than $20 each, used. The only other component I paid for was the steel rod for $5.

Drawings I had made for earlier versions of the circle scribing tool would have used a granite base and many more metal components and epoxy putty, but they would have cost a lot more money and would have been cumbersome and inflexible, since everything would have been glued in place. Granite was not cheap even for a small piece, and cutting it was even more expensive (and lead time to have it cut were too long for me). Furthermore, the granite base would have been very heavy, and fragile.

In the new simple design which I built in just one morning, I can take apart every component and store them away where they will not take up space. I can also customize the base and add elements to put some parts I want to scribe higher or lower. The two clamps allow me to adjust the height of the cutting tool where I want.

posted 02-08-2008 01:42 AM               

A close up view of the circle scribing cutting tool completed

posted 02-08-2008 01:51 AM               

And the final result:

posted 02-28-2008 06:16 PM               

The RCS engine exhausts edges have now also been corrected and smoothed.

Almost done. Now I will deepen the holes unto which the escape tower would normally be attached, and will add some tiny details there. And after that: the molds! I can't wait to see the first castings.

posted 03-06-2008 09:56 PM               

And the first test shot castings, from last night, enjoy:

posted 03-06-2008 10:01 PM               

Fresh new pictures from two days ago, just before pouring the molds I took these pictures.

Just to show you how impressive the pictures will look when the kit will be complete.
Enjoy!

posted 03-16-2008 06:01 PM               

The Orion CEV 606-C kit from Stratosphere Models is about complete (save for the base mold and for a few last duplicate small part molds and the avionics ring mold).

posted 03-17-2008 06:46 PM               

The view people may have from the ISS when the CEV will dock to the station.

A little more details about how I painted the solar panels:

I created three templates out of thin plastic sheets, the biggest template was the one to create the small grey triangle shapes, these were used as lose masks to airbrush the details. It was easy to align because of the folds in the solar panels. I bent that template vertically right in the middle to align precisely with the solar panels shape.

The second smaller template was used to create the small rectangle shapes and the third one for the black dot in the middle of the panels. I then liberally spread quantity of my little 'magical powder' all over the solar panels surface with my finger tip (it may not be very visible from the angles I took the photos, but under direct light, you would see a lot of sparkling. I used a pale blue sparkle powder I had got from an art store years ago for a totally different project.

posted 04-02-2008 09:54 PM               

Now I will be busy designing the instructions for the kit and the box art. I am going to order silicone to make the molds for the base this week as those were not made yet. There is still work to do on the avionics ring and a couple of molds I will modify somewhat. We are almost there!

I will also post an update about new documents I have found which are fresh from this year.

I have also started updating my website and adding the new pictures there.

posted 04-28-2008 06:17 PM               

This weekend, I have cast the last molds for the CEV Orion spacecraft: the avionics ring mold itself and a few smaller duplicate molds for the auxiliary rocket engines, etc.

posted 05-08-2008 04:57 PM               

The completed base (sorry if the pictures are a little dark, more bright they would wash out the details on the white parts):

posted 05-08-2008 05:29 PM               

More parts:

posted 06-02-2008 10:51 PM               

This is a slighlty hemispheric disk that represent the Moon which is a special extra option that allows my clients to customize the kit some more. The disk of the Moon will be cast in translucent resin which can be lighted with a small LED and a watch battery, making the model and the base stand out more and adding a little spectacular effect to it.

The standard disk featuring the CEV Orion raised letters will also be cast in translucent, tinted resin which can be lighted from behind (the color will be blue).

So now, modellers will have 3 choices of customization of their base for the model, the two translucent disks with the Moon and with the name of the kit, and as both of them are interchangeable (if it is not glued in place it is easy to change it for the 2nd decorative disk when you want to give the base a different look), or the peel-and-stick picture of the Moon which will be provided and will cover most of the surface of the base.

These two optional resin parts are only available to my pre-order customers. For the standard production version only one of them will be provided with the kit. So to anyone who still wants to pre-order before I finish the castings of the base, this is your chance to own that special custom part, you can still have those two special items included with your kit. I will sell the 2nd disk separately as an option to the clients who will buy the kit after the pre-order period (which is coming to end soon, as I am finishing the last molds). The base will also be available as a separately as an option for other kits that are already available from Stratosphere Models and for some future kits as well.

posted 06-02-2008 11:08 PM               

Here are preliminary pictures of what the Orion CEV kit from Stratosphere Models will look like with its base and with the translucent Moon disk, lighted!

I will take better pictures tomorrow (I am gluing the kit parts once more to show it in a more complete form and to remove all that tape from the photos and get a better shot with a better background).

I have cast the translucent disk with different colors and found out that the orange Moon (similar to the Automn Moon or to a lunar eclipse) shows the contrast between the seas and the cratered areas better.

You will only need to add two or three powerful white LEDs and small watch-size three volt batteries (one for each LED), and you'll have a very special lighted base with the Moon seas and craters showing.

I have started to cast the bases for the kits, this is one of the first samples, I cast it a dark charcoal color, I have got half of the bases cast so far and I am making more bases this week.

The kits that have been pre-ordered will also come with another translucent disk, featuring the name of the kit, so you can swap both of them to customize your base. Also, they will include one large stick-and-peel picture of the Moon, that can be used to decorate the base (instead of the translucent rings).

Those special custom parts will be included with the kits ONLY for those who have pre-ordered the kits. Since I am still casting bases to complete the pre-ordered kits this week, this is your last chance to get those special custom parts at a lesser price!

posted 06-04-2008 11:13 PM               

I have decided to make it standard part of the production Orion CEV kit (the 2nd translucent disk featuring the name of the kit will be the part that will be sold separately). So now, everyone will be able to get the Moon disk as standard part of the kit, including people who were not part of the pre-order offer.

I found out that the craters and seas show up with way more contrast when I turn the disk upside down (as seen here) (convex part down). The effect if particularly spectacular and noticeable even with room lights on.

posted 06-04-2008 11:16 PM               

The lighted Moon disk for the kit's base is now officially an integral part of the production kit (not just for the pre-order clients). The pre-order clients however will get an additional translucent disk featuring the name of the kit and the peel-and-stick photo of the Moon.

posted 09-18-2008 01:00 AM               

I have now made another version of the decorative translucent Moon disk for the Orion CEV kit available.

The new Moon disk is tinted yellow and as you can see from the picture, it does look as neat at the orange one, and shows good contrast.

I am making it available with the kit and you now can choose it when you buy your Orion CEV kit: with the orange Moon disk or with the yellow Moon disk.

I am also now offering a new version of the CEV Orion kit which include a transparent Command Module, so you can light it from the inside!! The new version made with a special transparent resin (which I can make transparent or tinted, per request) allows you to install white LEDs inside to illuminate those windows and make for a more striking model. I can also provide the model with a transparent main rocket nozzle, so you can light the engine too!