Torellian Invader (3" upscale) - Revision history

Danno at 23:30, 14 January 2026

2026-01-14T23:30:56Z

← Older revision		Revision as of 18:30, 14 January 2026
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	''January 9, 2026:'' I have the second fillet curing on the first test fin now (tacking the fin with JB Weld and then filleting with more JB Weld). I don't love JB Weld for the fillets. I am planning to test the second fin using JB Weld to tack on but thinner epoxy (maybe 30 minute BSI) for the fillets. I will need to tape wax paper over the back side of the fin slot when pouring the first fillet.		''January 9, 2026:'' I have the second fillet curing on the first test fin now (tacking the fin with JB Weld and then filleting with more JB Weld). I don't love JB Weld for the fillets. I am planning to test the second fin using JB Weld to tack on but thinner epoxy (maybe 30 minute BSI) for the fillets. I will need to tape wax paper over the back side of the fin slot when pouring the first fillet.

			''January 14, 2026:'' Updates:
			* Finalized a fin design that should work well. The slots are now just indentations that do not go all the way through the fin. When fillets are applied, I'll wait about five minutes for the epoxy to settle into the indentations before smoothing. Trapped air may prevent the indentation from fully filling, but hopefully this will still improve mechanical grip somewhat.
			* Tacked on the first of the outer fins - technically this is the "start of assembly" as these are the first two joined pieces that will be part of the finished rocket.
			* Started printing prototype parts for the canopy frame.
			* Ordered silver PETG filament for printing the final canopy frame (so it won't have to be painted).

	'''Immediate TODOs:'''		'''Immediate TODOs:'''
	* ~~Keep experimenting with~~ the ~~PETG~~ fins ~~to make sure that method will work~~		* Drill tube fins and bond the outer flat fins (in progress as of 1/14/2026)
	* Tweak tube fin jig design (~~tighten up the part that holds the flat fin~~) ~~and re-print~~
	* Design the side and ventral fins in CAD		* Design the side and ventral fins in CAD
	* Print ~~all the fins~~		* Print side and ventral fins
	* Drill tube fins and ~~bond the outer flat~~ fins		* Prototype the canopy and tweak / finalize its design (in progress as of 1/14/2026)
	* Prototype the canopy and tweak / finalize its design (~~I've been putting this off~~)

	<gallery mode="slideshow">		<gallery mode="slideshow">
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	File:TI3-tube-fins-cut.jpg\|Tube fins cut with new chop saw\|alt=Six red fiberglass tubes, 2.1 inches diameter and 10 inches long, with a chop saw in the background.		File:TI3-tube-fins-cut.jpg\|Tube fins cut with new chop saw\|alt=Six red fiberglass tubes, 2.1 inches diameter and 10 inches long, with a chop saw in the background.
	File:TI3-nose-sled.jpg\|Nose cone with TeleGPS sled\|alt=A black rocket nose cone with a sled extending from the shoulder, holding a TeleGPS.		File:TI3-nose-sled.jpg\|Nose cone with TeleGPS sled\|alt=A black rocket nose cone with a sled extending from the shoulder, holding a TeleGPS.
			File:TI3-first-fin.jpg\|First tube fin being tacked together (official start of construction, Jan. 14 2026)\|alt=A grey fin being glued to a red tube in a blue fin jig.
	File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.		File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.
	</gallery>		</gallery>

Danno at 17:00, 9 January 2026

2026-01-09T17:00:05Z

← Older revision		Revision as of 12:00, 9 January 2026
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	'''Immediate TODOs:'''		'''Immediate TODOs:'''
	* ~~Assemble the nose and update~~ the ~~sim with its actual weight~~		* Keep experimenting with the PETG fins to make sure that method will work
	* ~~Print drilling /~~ fin ~~jigs~~		* Tweak tube fin jig design (tighten up the part that holds the flat fin) and re-print
	* Even out the ~~tube~~ fin ~~lengths~~		* Design the side and ventral fins in CAD
	* ~~Weigh~~ the ~~tubes~~ and ~~update~~ the ~~sim with those weights~~		* Print all the fins
	* Drill ~~all~~ the ~~holes~~		* Drill tube fins and bond the outer flat fins
	* ~~Print tail rings~~ and ~~start dry fitting the tail parts~~		* Prototype the canopy and tweak / finalize its design (I've been putting this off)

	<gallery mode="slideshow">		<gallery mode="slideshow">

Danno at 16:57, 9 January 2026

2026-01-09T16:57:00Z

@@ Line 48: / Line 48: @@
 ''December 10, 2025:'' Reprinting the sled to correct a few minor issues, then the nose should be ready to assemble (and weigh). Finally set up the chop saw and cut all of the tubes (photo below). The tube fins will need to be sanded to even out their lengths.
-''December 11, 2025:'' It's taken several tries to get the sled to print properly. The last one is good, but the outer bracket broke as I was pulling it off the print bed. Also, between last night and today I think I have a first pass at all of the drilling and fin jigs.
+''December 11, 2025:'' It's taken several tries to get the sled to print properly. The last one is good, but the outer bracket broke as I was pulling it off the print bed. Also, between last night and today I think I have a first pass at designing all of the drilling and fin jigs.
 '''Immediate TODOs:'''

Danno at 04:03, 12 December 2025

2025-12-12T04:03:13Z

← Older revision		Revision as of 23:03, 11 December 2025
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	''December 10, 2025:'' Reprinting the sled to correct a few minor issues, then the nose should be ready to assemble (and weigh). Finally set up the chop saw and cut all of the tubes (photo below). The tube fins will need to be sanded to even out their lengths.		''December 10, 2025:'' Reprinting the sled to correct a few minor issues, then the nose should be ready to assemble (and weigh). Finally set up the chop saw and cut all of the tubes (photo below). The tube fins will need to be sanded to even out their lengths.

			''December 11, 2025:'' It's taken several tries to get the sled to print properly. The last one is good, but the outer bracket broke as I was pulling it off the print bed. Also, between last night and today I think I have a first pass at all of the drilling and fin jigs.

	'''Immediate TODOs:'''		'''Immediate TODOs:'''
	* Assemble the nose and update the sim with its actual weight		* Assemble the nose and update the sim with its actual weight
	* ~~Make~~ drilling / ~~sanding~~ jigs		* Print drilling / fin jigs
	* Even out the tube fin lengths		* Even out the tube fin lengths
	* Weigh the tubes and update the sim with those weights		* Weigh the tubes and update the sim with those weights
Line 61:		Line 63:
	File:TI3-printing-nose.jpg\|Lower part of nose being printed (yellow material is support and will be removed)\|alt=Photo of a black nose cone being printed on a Prusa Mk4 3D printer with yellow supports.		File:TI3-printing-nose.jpg\|Lower part of nose being printed (yellow material is support and will be removed)\|alt=Photo of a black nose cone being printed on a Prusa Mk4 3D printer with yellow supports.
	File:TI3-tube-fins-cut.jpg\|Tube fins cut with new chop saw\|alt=Six red fiberglass tubes, 2.1 inches diameter and 10 inches long, with a chop saw in the background.		File:TI3-tube-fins-cut.jpg\|Tube fins cut with new chop saw\|alt=Six red fiberglass tubes, 2.1 inches diameter and 10 inches long, with a chop saw in the background.
			File:TI3-nose-sled.jpg\|Nose cone with TeleGPS sled\|alt=A black rocket nose cone with a sled extending from the shoulder, holding a TeleGPS.
	File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.		File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.
	</gallery>		</gallery>

Danno at 23:59, 10 December 2025

2025-12-10T23:59:25Z

← Older revision		Revision as of 18:59, 10 December 2025
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	\|image = TI3-openrocket.png		\|image = TI3-openrocket.png
	\|diameter = 3.125 inches (79mm)		\|diameter = 3.125 inches (79mm)
	\|length = 5 ft. 2.5 in. (1.6 m~~) (tentative~~)		\|length = 5 ft. 10.5 in. (1.8 m)
	\|weight = 10 lbs. (4.5 kg) (estimated)		\|weight = 10 lbs. (4.5 kg) (estimated)
	\|motor-size = 54mm		\|motor-size = 54mm

Danno at 18:26, 10 December 2025

2025-12-10T18:26:35Z

← Older revision		Revision as of 13:26, 10 December 2025
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	''December 4, 2025:'' TeleGPS sled and upper nose printed; I'm still having some printability problems with the lower nose but getting closer, I hope.		''December 4, 2025:'' TeleGPS sled and upper nose printed; I'm still having some printability problems with the lower nose but getting closer, I hope.

			''December 5, 2025:'' Motor and motor hardware arrived. Still don't have a good print of the nose but I tried out the heat-set inserts and they work great.

			''December 9, 2025:'' Have a good print of the nose at 25% infill (to increase weight).

			''December 10, 2025:'' Reprinting the sled to correct a few minor issues, then the nose should be ready to assemble (and weigh). Finally set up the chop saw and cut all of the tubes (photo below). The tube fins will need to be sanded to even out their lengths.

	'''Immediate TODOs:'''		'''Immediate TODOs:'''
	* ~~Print~~ nose ~~parts (in progress)~~		* Assemble the nose and update the sim with its actual weight
	* ~~Declutter workshop (bin up other projects)~~		* Make drilling / sanding jigs
	* ~~Set up chop saw~~		* Even out the tube fin lengths
	* ~~Cut motor mount tube~~		* Weigh the tubes and update the sim with those weights
	* ~~Cut lower airframe tube~~		* Drill all the holes
	* ~~Test fit parachute~~ and ~~make decision on length of upper airframe tube~~		* Print tail rings and start dry fitting the tail parts

	<gallery mode="slideshow">		<gallery mode="slideshow">
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	File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.		File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.
	File:TI3-printing-nose.jpg\|Lower part of nose being printed (yellow material is support and will be removed)\|alt=Photo of a black nose cone being printed on a Prusa Mk4 3D printer with yellow supports.		File:TI3-printing-nose.jpg\|Lower part of nose being printed (yellow material is support and will be removed)\|alt=Photo of a black nose cone being printed on a Prusa Mk4 3D printer with yellow supports.
			File:TI3-tube-fins-cut.jpg\|Tube fins cut with new chop saw\|alt=Six red fiberglass tubes, 2.1 inches diameter and 10 inches long, with a chop saw in the background.
	File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.		File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.
	</gallery>		</gallery>

Danno at 17:17, 4 December 2025

2025-12-04T17:17:07Z

← Older revision		Revision as of 12:17, 4 December 2025
Line 39:		Line 39:

	''December 1, 2025:'' Made the first big round of CAD fixes on the nose and getting close to having the flight-ready parts.		''December 1, 2025:'' Made the first big round of CAD fixes on the nose and getting close to having the flight-ready parts.

			''December 4, 2025:'' TeleGPS sled and upper nose printed; I'm still having some printability problems with the lower nose but getting closer, I hope.

	'''Immediate TODOs:'''		'''Immediate TODOs:'''
	* Nose cone CAD fixes (in progress)		* Print nose parts (in progress)
	* Print ~~new~~ nose parts (in progress)
	* Declutter workshop (bin up other projects)		* Declutter workshop (bin up other projects)
	* Set up chop saw		* Set up chop saw
Line 48:		Line 49:
	* Cut lower airframe tube		* Cut lower airframe tube
	* Test fit parachute and make decision on length of upper airframe tube		* Test fit parachute and make decision on length of upper airframe tube
	* Work on this wiki page

	<gallery mode="slideshow">		<gallery mode="slideshow">
	File:TI3-openrocket.png\|OpenRocket design\|alt=Screenshot of OpenRocket showing the upscaled Torellian Invader.		File:TI3-openrocket.png\|OpenRocket design\|alt=Screenshot of OpenRocket showing the upscaled Torellian Invader.
	File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.		File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.
			File:TI3-printing-nose.jpg\|Lower part of nose being printed (yellow material is support and will be removed)\|alt=Photo of a black nose cone being printed on a Prusa Mk4 3D printer with yellow supports.
	File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.		File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.
	</gallery>		</gallery>

Danno at 23:09, 2 December 2025

2025-12-02T23:09:27Z

← Older revision		Revision as of 18:09, 2 December 2025
Line 38:		Line 38:
	''November 29, 2025:'' Ordered stickers from StickerShock.		''November 29, 2025:'' Ordered stickers from StickerShock.

	''December 1, 2025:'' Made the first big round of fixes on the nose and getting close to having the flight-ready parts.		''December 1, 2025:'' Made the first big round of CAD fixes on the nose and getting close to having the flight-ready parts.

	'''Immediate TODOs:'''		'''Immediate TODOs:'''

Danno at 23:09, 2 December 2025

2025-12-02T23:09:12Z

← Older revision		Revision as of 18:09, 2 December 2025
Line 35:		Line 35:

	''November 28, 2025:'' Lost momentum on this project again. Ordered the motor and motor case on a Black Friday sale from BuyRocketMotors.com. Rearranging the task list to put some more fun stuff up front to maintain my enthusiasm. To that end, starting 3D printing prototypes and iterating on the nose cone design.		''November 28, 2025:'' Lost momentum on this project again. Ordered the motor and motor case on a Black Friday sale from BuyRocketMotors.com. Rearranging the task list to put some more fun stuff up front to maintain my enthusiasm. To that end, starting 3D printing prototypes and iterating on the nose cone design.

			''November 29, 2025:'' Ordered stickers from StickerShock.

	''December 1, 2025:'' Made the first big round of fixes on the nose and getting close to having the flight-ready parts.		''December 1, 2025:'' Made the first big round of fixes on the nose and getting close to having the flight-ready parts.
Line 51:		Line 53:
	File:TI3-openrocket.png\|OpenRocket design\|alt=Screenshot of OpenRocket showing the upscaled Torellian Invader.		File:TI3-openrocket.png\|OpenRocket design\|alt=Screenshot of OpenRocket showing the upscaled Torellian Invader.
	File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.		File:TI3-nose-CAD.png\|CAD of nose cone (3D printed in three pieces)\|alt=Screenshot of Autodesk Fusion 360 showing a rocket nose cone split into three parts.
			File:Torellian-invader-catalog.jpg\|The Estes catalog page for the Starfighter Combo Kit\|alt=A page from an Estes catalog around 1980, showing the Torellian Invader and Orion Starfigher sold as a combo for eight dollars.
	</gallery>		</gallery>

Danno at 23:06, 2 December 2025

2025-12-02T23:06:27Z

← Older revision		Revision as of 18:06, 2 December 2025
Line 13:		Line 13:

	This is another upscale of my [[Torellian Invader]], this time built around a three inch fiberglass airframe. My goal is to have the rocket finished and ready to fly for [https://ldrs44.org/ LDRS 44] in April, 2026. It is expected to fly on an AeroTech K805 Mojave Green motor.		This is another upscale of my [[Torellian Invader]], this time built around a three inch fiberglass airframe. My goal is to have the rocket finished and ready to fly for [https://ldrs44.org/ LDRS 44] in April, 2026. It is expected to fly on an AeroTech K805 Mojave Green motor.

			== Build Progress ==

	I am keeping a detailed build diary - I won't post the whole thing here, but this is an abridged version. The project has had some stops and starts, and I've changed my mind about some things as I went along.		I am keeping a detailed build diary - I won't post the whole thing here, but this is an abridged version. The project has had some stops and starts, and I've changed my mind about some things as I went along.

	June 17, 2025: Initial brainstorming. I was initially thinking about building the rocket a cluster with small (24mm or 29mm) motors in some or all of the tube fins, but I've decided that's a bad idea, at least for now.		''June 17, 2025:'' Initial brainstorming. I was initially thinking about building the rocket a cluster with small (24mm or 29mm) motors in some or all of the tube fins, but I've decided that's a bad idea, at least for now.

	July 11, 2025: Figuring out the tube fin attachment in detail. There will be two 3D-printed rings that slide over the airframe with cutouts to cradle the tube fins, and bolts from the inside of the tube fin into T-nuts inside the airframe.		''July 11, 2025:'' Figuring out the tube fin attachment in detail. There will be two 3D-printed rings that slide over the airframe with cutouts to cradle the tube fins, and bolts from the inside of the tube fin into T-nuts inside the airframe.

	July 13, 2025: Decided to 3D-print the entire nose cone rather than start with a fiberglass nose cone. Also settled on having a TeleGPS in the nose and a BlueRaven in the coupler. I was initially picturing an external power switch for the TeleGPS (so it could be powered off without pulling the sled out of the nose) but decided against that.		''July 13, 2025:'' Decided to 3D-print the entire nose cone rather than start with a fiberglass nose cone. Also settled on having a TeleGPS in the nose and a BlueRaven in the coupler. I was initially picturing an external power switch for the TeleGPS (so it could be powered off without pulling the sled out of the nose) but decided against that.

	July 16, 2025: Added rail buttons to the design, inside one of the tube fins. This requires a small cheat - the original Torellian Invader had tube fins at 3 and 9 o'clock relative to the canopy, but in order to put the rail buttons opposite the canopy on this design, I need to have tube fins at 6 and 12 o'clock.		''July 16, 2025:'' Added rail buttons to the design, inside one of the tube fins. This requires a small cheat - the original Torellian Invader had tube fins at 3 and 9 o'clock relative to the canopy, but in order to put the rail buttons opposite the canopy on this design, I need to have tube fins at 6 and 12 o'clock.

	July 30-31, 2025: Made more progress on the CAD model and ordered most of the materials from Wildman and McMaster-Carr. I also bought a cutoff saw for cutting the tubes.		''July 30-31, 2025:'' Made more progress on the CAD model and ordered most of the materials from Wildman and McMaster-Carr. I also bought a cutoff saw for cutting the tubes.

	September 18, 2025: Coming back to this project after a break and planning next steps. Another part of the design that fell by the wayside is an external camera shroud. I wanted to have a camera on the same side as the canopy, looking back past the "pilot" (in this case, a Greedo action figure) and possibly dress up the shroud so it looked like a laser cannon or something. I finally decided that would add too much weight and drag on that side, so I gave up on that idea.		''September 18, 2025:'' Coming back to this project after a break and planning next steps. Another part of the design that fell by the wayside is an external camera shroud. I wanted to have a camera on the same side as the canopy, looking back past the "pilot" (in this case, a Greedo action figure) and possibly dress up the shroud so it looked like a laser cannon or something. I finally decided that would add too much weight and drag on that side, so I gave up on that idea.

	September 25-27, 2025: Came up with the idea of embedding a wing nut in the tip of the nose and printing over it, so the threaded rod can screw in.		''September 25-27, 2025:'' Came up with the idea of embedding a wing nut in the tip of the nose and printing over it, so the threaded rod can screw in.

	October 9, 2025: Finished CAD on the nose cone while visiting family in Las Vegas.		''October 9, 2025:'' Finished CAD on the nose cone while visiting family in Las Vegas.

	November 28, 2025: Lost momentum on this project again. Ordered the motor and motor case on a Black Friday sale from BuyRocketMotors.com. Rearranging the task list to put some more fun stuff up front to maintain my enthusiasm. To that end, starting 3D printing prototypes and iterating on the nose cone design.		''November 28, 2025:'' Lost momentum on this project again. Ordered the motor and motor case on a Black Friday sale from BuyRocketMotors.com. Rearranging the task list to put some more fun stuff up front to maintain my enthusiasm. To that end, starting 3D printing prototypes and iterating on the nose cone design.

	December 1, 2025: Made the first big round of fixes on the nose and getting close to having the flight-ready parts.		''December 1, 2025:'' Made the first big round of fixes on the nose and getting close to having the flight-ready parts.

	Immediate TODOs:		'''Immediate TODOs:'''
	* Nose cone CAD fixes (in progress)		* Nose cone CAD fixes (in progress)
	* Print new nose parts (in progress)		* Print new nose parts (in progress)