Dyna-Soar with Titan Booster by Austin_Aerospace_Education

Last crawled date: 3 years ago

This is a remix utilizing multiple sources including:
Richard Cornford who had created a 1/96 scale Dyna-Soar with the Titan Adapter https://www.thingiverse.com/thing:3174974
Scott Mills who had recreated the parts to build the Estes Titan II https://www.thingiverse.com/thing:2845691
The JimZ web site to download a copy of the original Estes Gemini instructions http://www.spacemodeling.org/jimz/est1978.htm
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We had always wanted to build a flying model of the X-20 Dyna-Soar. It is a unique spacecraft that unfortunately was cancelled before it could fly. Since we wanted a flying model it made sense to see if we could build one of the earlier Titan II concept vehicles due to its large fins.
To begin we had a scale 3-view drawing from the original Dyna-Soar/Titan II design by the Martin Company. This led us to find Richard Cornford who had created a 1/96 scale Dyna-Soar with the Titan Adapter. Another modeler by the name of Scott Mills had recreated the parts to build the Out of Production Estes Titan II kit. That then led us to the JimZ web site to download a copy of the original instructions. We found that the Estes model was designed around a BT-60 body tube.
Based on this we had a basic idea of what we would need to create a flying model. Using the BT-60 outer tube dimension and comparing it to the original blueprint, we could begin to create the plans for the Dyna-Soar. This allowed us to create the fins. They were unusual as there are two large fins (which are in line with the wings of the Dyna-Soar) and two smaller fins.
We also had to scale up the Dyna-Soar 3D print, as its original size was too small for the BT-60 body tube. We used the scaling feature in the MatterControl software to upscale the base of the transition to the same diameter as the BT-60. In addition, we needed to add a nose cone shoulder to allow it to stay on the BT-60 body tube and provide a place to attach the parachute and shock cord. Once this was done, we had a basic idea of what our model would look like. The question was would it fly?
To answer that question we created a basic design in OpenRocket. It is not exact as OpenRocket was not able to add the winglets on the Dyna-Soar. However, it should be close enough to determine stability and approximate performance. These initial simulations revealed that the standard 18mm motor used in the Estes Gemini Titan would really be underpowered for this size and weight model. So we adjusted the design to use the large 24mm motors.
Our first print of the Dyna-Soar nose was using a standard setting to make sure it would fit the rocket. We just recently printed a second copy using extra fine settings to get the best print possible. We also reduced the fill from 22% to 10% to help reduce the weight as well as thin the walls and top and bottom (The OpenRocket report shows the performance based on the original print, not the updated print).
We knew we wanted a display stand that would spotlight the model. We combined the display engine nozzles from the Titan file and mounted them on to a display block. During our searches for information on the Dyna-Soar we found a really nice logo/shield. We decided to add that to the display stand in a raised relief pattern. This completed the 3D printing aspect of the build.
The fins were cut from bass wood instead of balsa wood. This should give the model some added strength. As this is a sport scale model we simply rounded the leading and trailing edges of the fins. We glued the fins on using the alignment guide generated in OpenRocket.
There are two sets of conduits, each having two sections. They are located on body tube according to the alignment guide generated in OpenRocket. We used the dimensions given in the Estes Titan instructions to space the conduits the proper distance apart. The conduits are attached using plastic model cement. The launch lugs were cut to size and glued on using wood glue.
The basswood fins received a coat of thinned wood filler and were sanded smooth. The same was done to the spirals on the body tube. The model was then sprayed in sanding primer and sanded smooth.
With the Dyna-Soar nose cone removed, we plan to spray a basecoat of white to the body and fins. The silver areas will be masked off and painted. Using the decal file from the JimZ’s site, we plan to create a set of decals using our ink-jet printer.
We look forward to finishing this model in the near future and updating this project.