TThe alt-bay will be similar to the one I used on Tall Daddy.
7/15/04 - Today I made the alt-bay tube coupler. Using an extra Sono tube, I cut a 10 inch section off the top. Then using the formula (OD - ID)*pi to cut out the size piece I need for the tube to fit back into the body tube. After making and drawing the lines, I cut the small approximate 1 inch piece out using the table saw. Then I taped the outside ends together and cut a small piece of fiber glass to fit the inside with about a 1 inch overlap on each side of the cut. Next I epoxied the two sides together and set it aside to cure.
7/22/04 - Today I had time to make up the alt-bay bulk heads. The bulkheads are 1/2 inch plywood that fit right on top of the alt-bay tube coupler. To keep it centered, I cut a smaller ring from 1/8 inch plywood and then epoxied them together using the middle center hole so they would be centered on the bulkhead.
7/24-7/27 - With a few pockets of time between work and home life, I managed to get a few things done. The next item was to drill the holes for the alt bay bulkheads. I was going to go with two, but since this was a heavier rocket, I went with 4 all-thread supports. Next I put in the 2 u-bolts on the top and bottom plates. After measuring out the alt bay height, I cut 4 pieces of 1/4-20 all thread. I have several 1/4-20 large T-nuts so I used them on the bottom to make a cleaner more flush appearance. Then I put a nut and washer on the back side to keep it from going anywhere. I also loc-tight'ed the all thread. Along with that I sealed all the holes with silicon and well as both lips of the bulkhead plates.
8/3/04 - I had some time to work on the Alt-bay. I was measuring the center ring. This is the outer ring that helps join the upper and lower body tubes together. I wanted to put the switch in so it was below the ring for a better profile. I drilled through both the outer rings and alt-bay couples with a 1/2 inch drill bit. This allowed the inner switch part to fit but still the shoulder of the switch stuck out too far. So I took the ring off and used my dremel tool to widen the hole just enough so the shoulder would slide past. I then test fitted the ring and epoxied it to the alt-bay coupler tube. I then installed the switch. This will be used to turn on both altimeters. The next item was to get the alt-bay end plates ready for electronics. I drilled two holes for the light bulb sockets that I use for electrical connections from inside the alt-bay. I also drilled two more holes and installed 6-32 T-nuts to hold the PVC cap charge holders.
8/6/04 - While waiting for epoxy to setup on the fin can I did some work on the alt-bay. I measured out where the bulkhead plates ended up inside both upper and lower body tubes. I then marked the out side and measured around to make four holes for each plate. Then I drilled out the holes with a small pilot hole bit to make sure I drilled in the right place. Then I drilled out the holes for the furniture nuts and installed them. I also drilled out the body tube holes to be slightly bigger than the #8-32 screws I choose to use for this project. After installing all eight nuts, I checked the fit and it was great. I made sure to line up the upper and lower bolts and also centered the power switch. After that we together, I measured the volume of the alt-bay and figured out the size holes needed for both Missile Works RRC2 altimeters and measured to drill 3 holes around the body tube to drill out the holes. I then centered them to be away from the bolts and they came out great.
8/8/04 - Yesterday and today, I worked on the alt-bay some more. I cut out the board to mount the electronics and mounted it to the all thread inside the alt-bay. I also mounted the two altimeters to test them and make sure they will work.
