ss1_instr.pdf

Assembly instructions for

SpaceShipOne

The SpaceShipOne story

In 1996 the X-Prize competition was initiated by a group of American business leaders. It

offered a US$10 million award for the construction of a privately-funded vehicle capable of

taking three people to an altitude of 100 kilometres, returning them safely to earth, and

repeating the flight within two weeks. Over twenty teams from around the world subsequently

entered this competition. In April 2003, aircraft manufacturer Scaled Composites LLC, backed

by funding from entrepreneur Paul Allen, joined the race with an innovative launch system

known as Tier One.

Tier One is the creation of Scaled president Burt Rutan, well known for his futuristic aircraft designs like the Beech Starship and the globe-

circling Voyager. RutanÓs solution to the X-prize problem is a two-stage system consisting of a jet-powered carrier aircraft called White Knight,

and a rocket-propelled spacecraft known as SpaceShipOne. The White Knight is to carry SpaceShipOne to an altitude of about 15 km. (50,000

ft.), at which point the rocket craft is released and flies under its own power to reach the 100 km. target height.

The design of SpaceShipOne emphasizes simplicity and low cost. As with all Rutan creations it is visually striking, with stubby main wings and

a twin-boom tail layout. The innovative rocket motor uses a rubber-like fuel with nitrous oxide gas as an oxidizer, providing safer and easier

handling than conventional rocket fuels. For re-entry, the spacecraftÓs entire tailplane and the rear part of the wing tilt upward to a high-drag

ÒfeatherÓ configuration. As it approaches the ground, the tail returns to its normal flying position, and SpaceShipOne glides to a runway landing

like a conventional aircraft. There are no control surfaces on the main wing, flight control being provided by stabilators on the tail booms and

by outward-deflecting rudders.

SpaceShipOneÓs sealed cabin is a ÒshirtsleeveÓ environment; the three occupants do not wear pressure suits, though oxygen masks are provided

for emergencies. The cockpit layouts of White Knight and SpaceShipOne are similar, allowing pilots to train for the rocket plane while flying

the carrier aircraft.

The flights take off and land at Scaled CompositesÓ home base at Mojave California, and rocket launch and re-entry take place in the airspace

of nearby Edwards Air Force Base. The first flight of the White Knight/SpaceShipOne combination occurred on May 20, 2003, with the first

release and glide test of SpaceShipOne on August 7. On December 17, 2003 the first rocket-powered flight occurred, reaching a speed of Mach

1.2. SpaceShipOne was slightly damaged due to a landing gear failure after this flight, but repairs and modifications were made, and on 21 June

2004, pilot Mike Melvill took SpaceShipOne beyond 100 km. altitude, the boundary of space, and returned safely to earth.

The team was now ready to attempt the two flights that would win the X-Prize. The first took place on 29 September 2004, with Mike Melvill

again at the controls and less than a week later, on October 4, Brian Binnie piloted SpaceShipOne to victory.

The Model

This model is a 1:48 scale replica of Scaled CompositesÓ SpaceShipOne. Two versions are available, depicting either the first powered test in

December 2003 (parts document ss1_parts.pdf) or the X-Prize qualifying flights in September and October 2004 (parts document ss1x_parts.pdf).

Print out the parts document on 8.5"x11" or A4 size white paper card stock suitable to your printer. 67 lb. cover stock (approx. 8.5 thousandths

of an inch or 0,2 mm thick) is recommended.

A word of caution: this model is not suitable for assembly by young children, due to the use of sharp tools and the complexity of some assembly

steps. Previous experience with card modeling is recommended. If you have any comments or suggestions regarding this kit, I can be reached by

e-mail at models@currell.net

Tools

Before beginning, you will need the following tools and materials:

a) a sharp knife for cutting

e) a scoring tool or blunt knife for creasing the fold lines

b) a flat cutting surface

f) a glue applicator such as wooden toothpicks or a small paintbrush

c) a ruler or straight edge

d) white glue

Hints

a) Select a well-lit, comfortable work area that will remain undisturbed when you are not there.

b) Keep your hands and tools clean when working, to avoid getting glue on visible parts of the model.

c) ItÓs easier to stay organized if you only cut out those parts you need for each step.

d) Make sure your knife is sharp. When cutting straight lines, use a straight-edge.

e) Study the diagrams carefully, and always test-fit the parts before applying glue.

ss1_instr.pdf v1.1 ¨ October 2004 by Ralph Currell www.currell.net

Page 1 of 5

Assembly

In these instructions, the directional terms are from the pilotÓs viewpoint facing in the direction of travel. ÒPortÓ and ÒstarboardÓ refer to left and

right sides respectively. Scoring of parts is indicated by thin black lines outside the partÓs outline, and by dashed or shaded lines on the partÓs

surface. Score parts before cutting them out. In the diagrams, subassemblies are identified by a number within a circle (e.g. ), corresponding

to the step in which it was assembled.

Assemble and join the front and centre fuselage segments (steps 1Î3). Each segment comprises an outer surface (the ÐskinÑ of the aircraft), a

connecting strip and (except for the nose segment) a circular former to provide strength and maintain the segmentÓs shape. To construct a typical

segment (as shown in step 1) glue the connecting strip to the inside of the surface part. It is recommended that these parts be curled in the

direction of their final shape before gluing (this will prevent buckling when the combined parts are curved later). The strips have a thin line along

the centre, which must be lined up with the respective edges of the surface part. The segment is then rolled so the edges butt together and are

held by the connecting strip. Once dry, the former is glued inside the assembly, as close to the narrow end as necessary to achieve a snug fit. Note

that on the rear segments, the former is not a perfectly circular. In this case the blue printed arrow on the former must line up with the body

seam. Add approximately 5 grams weight (equivalent to two US pennies) into one of the nose segments to ensure the model balances properly

on its landing gear.

At this point choose whether the landing gear is to be built in the raised or lowered position.

Gear up: assemble the main gear fuselage segment (step 5) without opening the gear doors, and skip to step 9.

Gear down: Cut out the landing gear doors in segment surface A18 (step 4), and glue wheel well plates B10 and B11 to the inside, such that the

printed shape shows through the door cutouts. Assemble the segment (step 5), then assemble and attach the landing gear support to the inside

bottom of the segment (step 6), such that the side flaps are positioned at the bottom edge of the rectangular cutouts in the wheel well plates.

Score and fold the wheel legs (step 7), then insert through the holes in the fuselage segment (step 8), gluing to the flaps on the internal support.

The legs should extend at a 45 degree angle below the horizontal when viewed from the front (see diagram). Wrap the wheel supports C11 around

the end of the legs as shown.

Assemble and join the rear fuselage segments (step 9) to the front fuselage. The shape of parts B21 and B22 differ depending on which version

of the parts layout is used. Form the front and rear wing spars (step 10) and glue into the fuselage holes so that they protrude the same length

on each side.

Assemble the starboard wing internal frame (step 11). Slide the frame on and off the fuselage wing spars to ensure it fits without difficulty, then

attach wing surface (step 12). Note that the larger rib is located at the inboard edge of the wingÓs bottom surface. Glue the frame to the bottom

surface and fold the top surface over, ensuring that the corner points touch at the outer rear wing. Attach the trailing edge strip C20.

Attach the completed wing to the fuselage (step 13) then assemble and attach the port wing (mirror image of the starboard).

Assemble the internal frame for the starboard tail boom (step 14) by gluing spacer strips C12 and C16 between side plates C4 and C6. Ensure

that the strip labels ÒtopÓ and ÒbottomÓ face in the correct direction. Attach the outer surface C28 to the internal frame (step 15). Precise location

is important here, since the edge tabs of this piece wrap over the top and bottom of the boom and interlock with the surface piece on the

opposite side. It is recommended that the tabs be curled in the direction of their final shape before attaching this piece. Ensure that the

horizontal rudder line is aligned with the blue arrow printed on the internal frame. Carefully wrap the tabs over and attach to the blue markings

printed on the opposite side of the frame. In a similar manner attach the surface piece C30 and wrap the tabs to the opposite side of the boom.

Add end plate C24.

Glue the completed boom to the starboard wing (step 16), ensuring that the blue locating shape printed on the end of the boom is covered by

the wing, and that the front edge of the boom lines up with the hinge line printed on the wing. Curl and attach wingtip C14. Assemble and attach

the port boom and wingtip (mirror image of the starboard).

(Step 17) Fold the starboard horizontal stabilizer frame B26, and wrap inside the stabilizer surface B16, ensuring the larger rib is placed at the

inboard edge of the surface piece. Attach the trailing edge strip C19 and the fence B24. Glue the horizontal stabilizer to the printed locating mark

on the starboard boom (step 18), then build and attach the port horizontal stabilizer as a mirror image of the starboard. Attach the triangular

strakes C27 to the printed locating marks in front of the horizontal stabilizers.

Glue together the inner and outer rocket cone surfaces (step 19), and roll into shape. It will probably be necessary to trim the inner surface edge

slightly to achieve a good fit for the inner and outer seams. Glue into the opening at the rear of the fuselage. Fold the various surface details as

shown and attach to the printed locating marks on the fuselage.

The final steps are optional depending on whether the landing gear is in the raised or lowered position.

Gear down: Assemble the wheels and attach to the ends of the landing gear legs (step 20) . Fold the support struts and attach the narrow end

to the markings on the rear edge of the legs, and the wide end into the wheel wells. Glue the forward landing gear doors to the front edge of the

legs, and the rear doors to the fuselage behind the wheel well opening. Assemble the nose skid and skid strut (step 21) and attach to the printed

locating marks on the underside of the front fuselage.

Gear up: Assemble the nose skid (step 22) and glue along the underside of the front fuselage as shown.

ss1_instr.pdf v1.1 ¨ October 2004 by Ralph Currell www.currell.net

Page 2 of 5

Typical fuselage segment

Front segments

A11+A12

A7+A8

A10

A14 A13

Optional :

If building with landing gear

extended, insert 5 grams

(2 pennies) for nose weight.

Centre segment

Optional (landing gear down)

Open landing gear doors

A20+A27

(each end)

Cut open landing gear doors

along printed lines and glue

B10 and B11 to inside surface.

B11

A18

A22

A21

Ensure "front" arrows on

A21 and A22 point in same direction.

B10

Main gear segment

Optional (landing gear down)

Landing gear support

Position flaps at

bottom edge of

rectangular cutouts.

Optional (landing gear down)

Main wheel legs (2 pieces)

B5+B6

(insert so that printed arrow

lines up with body seam)

C8, C9

(end view, fold

as shown)

A17

A15 A16

A19

Align printed

arrow with

body seam.

Optional (landing gear down)

Attach legs

C11

(2 places)

Rear Segments

B1+B2

(printed arrow lines up

with body seam, dark

printed circle faces rear)

B21

Early

version

(ss1_parts.pdf)

B22

B21

45 °

Later

version

(ss1x_parts.pdf)

Front view

B22

Front view

Side view

ss1_instr.pdf v1.1 ¨ October 2004 by Ralph Currell www.currell.net

Page 3 of 5

C8, C9

(end view, fold

as shown)

Wing spars

Starboard wing

internal frame

C26

Attach wing surface

to internal frame

Outboard corner points

meet when wing

surface is folded over.

B23

B17

C25

B18

Rib placed at

inboard edge of

bottom wing surface

C20

Starboard boom

internal frame

(non-inked side shown)

Attach wings to fuselage

Assemble port wing

as mirror image

of starboard.

C16

C12

B25

o ut er st ar bo a rd

B19,B20,C1,

C3,C25,C26

C21

Attach outer surface

to internal frame

Wrap tabs to attach to

blue locating marks.

inner starboa rd

o ut er s tar bo a rd

C24

Align printed line

with arrow on

inner frame.

C28

Curl tabs before

attaching to inner frame.

C30

Curl tabs before

attaching to

inner frame.

ss1_instr.pdf v1.1 ¨ October 2004 by Ralph Currell www.currell.net

Page 4 of 5

Attach booms

C13

Starboard horizontal

stabilizer

B16

C5,C7,C12,C16,

C24,C29,C31

Assemble as mirror image

of starboard boom.

B26

Place rib at

inboard edge of

bottom wing surface

B24

Locate front edge of boom

at printed hinge line on wing

C14

C19

Attach horizontal stabilizers

and strakes

Rocket cone and

surface details

(Inked side

facing down)

A26

A24

Fold to double thickness

then cut out shape.

A23

Fold as shown

(Inked side

facing up)

C27

Trim inside surface

edge if necessary to

eliminate gap when edges

are brought together.

B15,B27,

B24,C19

C27

Early

version

(ss1_parts.pdf)

Glue to locating

mark on bottom

centreline.

Optional (landing gear down)

Main landing gear details

A25

Fold to double thickness

then cut out shape.

Later

version

(ss1x_parts.pdf)

C10

Fold to double thickness

(2 pieces)

Optional (landing gear down)

Nose skid

C15

(2 pieces)

C23

(mirror of C22 on

other side of fuselage)

B12

C22

B14

Wrap around B13 so that

dark surface faces outward.

B13

C17

C10

Optional (landing gear up)

Nose skid

C18

B12

C15

ss1_instr.pdf v1.1 ¨ October 2004 by Ralph Currell www.currell.net

Page 5 of 5

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