posted 09-06-2003 10:37 AM            

Here is the problem! We don't know how to create a good reproduction of the ribbed skin of the capsule. Our preference is to try and recreate the skin with panels of aluminum or tin so it has the feel of the real thing.

posted 09-10-2003 10:53 AM            

After a lot of discussion we have decided to try and press some thin steel panels. After looking at photos of a real capsule, it looks as though we need three sizes of panel.

If we are successful, I'll post the results. I'll also post some photos of the project for anyone interested.

posted 11-28-2010 04:02 PM               

Here's the deal, we were going to have one donated for our museum but it appears that that isn't going to happen. So, now that I've bragged about it to a number of people, it looks like we will be building one from scratch by ourselves.

Like everyone else that has attempted this, I've scoured the net, found everything I can, pulled every book out of our library, printed off volumes of photos and every basic blueprint available.

There really isn't much out there though: the skin or shingles.

The outer skin is obviously going to be the most challenging part. Fortunately, I've been fabricating for the past 32 years and own a fabrication shop. I will be making a set of adjustable dimple dies to form the outer shell, we'll be making it out of thin sheet metal. Anyone out there have actual dimensions of the 'dimples' and/or outer panel dimensions?

I know a number of you have taken measurements from actual spacecraft. Care to share those with us?

This project will start in mid January. I hope to get some real close up shots during a trip to Houston, Huntsville and KSC in a few weeks but actual dimensions will be the key to making this one of those 'WOW' factors when people see it on display. We will not be doing just the main capsule but the retro pack and escape tower as well.

Like others that have said they will post their results (yet I haven't seen any, all the links posted are no longer valid) we will post ours. If for no other reason than to keep us on the ball and get it done. I just need to figure out how to post photos, it's been a pain for me ever since I joined the site.

posted 11-29-2010 01:27 AM               

When I did SFX I helped build full scale mockups of the Apollo Capsule and LEM (Apollo 13) the Mercury Capsule and the Space Shuttle (from the payload bay forward) They were mainly fiberglass which works the best and is the cheapest, easiest and most durable material to work with.

posted 01-22-2011 06:22 PM               

The first shot is obviously a vintage photo of the actual thing and the second one is what I came up with here in the shop.

posted 01-23-2011 10:22 AM               

Someone needs to model them in a CAD program and then fabricate them. This is obviously best done on a CNC machine. This involves hundreds of hours of work which is why you don't see them everywhere. The few companies that have done it charge A LOT for their work. Movie props are expensive!

I have all the computer models finished, all of the 1/4 molds finished, and some of the full size molds made. We are in the process of testing all the molds in 1/4 scale for fit and finish before we spend hundreds of hours of CNC router time finishing the full scale ones. My sample shingles have been test fit on an actual capsule and are nearly indistinguishable from the actual ones. We are currently preparing to finish the full size molds.

The plan has always been to provide the parts for free, to the right projects and for others that help contribute. This has never been intended to be a profitable venture. I have given away dozens of shingles, full size and quarter scale, with promises of something in return and never hear another word...

I have told many people that I would help, if they contributed. Of course no one ever follows through. Everyone wants something for free, which is expected.

I work on my Mercury Project every day. Even if its for the Engineering paper model, work for the hundreds of computer drawings and models I have created, the many spreadsheets I have organizing the hundreds of parts, or sorting and reviewing the thousands of photos I have to visualize part designs. A few builders have followed me along and have received everything I have promised them.

In the last few years, I started a new career, bought a house that needed major renovation, and adopted two toddlers. I have spent hundreds, perhaps thousands of hours on this project and have several friends that have contributed hundreds of hours to it. It comes along as it comes as we all have other lives. It has all been for free and freely shared.

posted 01-23-2011 12:35 PM               

Actually, our museum effort has only been in the works since June of 2008 and the capsule project just got started about a month ago. I'll be starting on the interior structure next and will certainly post photos for all to see. That's when the thing will start to take shape.

My original offer still stands to put my fabricating shop to use for your efforts as well, if there's anything that I can assist with anyway. Not really looking forward to the shingles part of it but we'll take it one step at a time.

We just returned from a trip where we took hundreds of photos and measurements of every Mercury capsule we could get close to. Whether or not this turns out to be a big help or not remains to be seen. It's the advice I'm getting from guys like you on this forum that have proven to be helpful so far. So thanks to everyone who's contacted me with advice.

posted 01-30-2011 03:12 PM               

It's taken about 14 hours to get to this point.

posted 02-01-2011 10:21 AM               

As stated earlier, the shingles are going to be the real challenge here. If I could afford to have them made for us I would gladly skip that process. We might still look into it but I fear the cost will drive me to make them here. We'll see when we get to that point.