Assembly Instructions for STS-110 payload
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1 2008 Assembly Instructions for STS-110 payload
2 IMPORTANT NOTE TO MODELERS The making of this model requires the use of the X-acto knife (craft knife) and tweezers, besides a simple scissor. Also important, get a lamp with a magnifying glass when working on small pieces. The photos shown on this manual are from my draft models on scales 1:144 and 1:100. In general, the building steps apply for both scales with the exception of certain details on the 1:100 model. The download file for the STS-110 mission consists of 3 paper models for the S0 truss: 1- A Payload bay model, which has no interior elements. (1:144 scale) 2- A Space Station version, which is more complete, with interior details (1:144 scale) 3- A Space Station version in 1:100 scale, which is more detailed, specially the interior. The Mobile Transporter also is available for both scales, too. Extensive research was done in order to design and build this model, not to mention the time and long night hours to assemble these 3 models for this presentation. Comments are welcomed. Thanks and enjoy it!
3 Familiarization with the S0 truss element A 1 B 3 C D E 2 G F H 4 I
4 J K 5 L 6 M N Red arrows indicate SIDES of S0 truss. From top to bottom: SIDE 1: Keel support and Drag link (A) and 3 DDCUs (B) SIDES 2 and 3: Node 2 umbilicals (C ), Node 3 umbilical (D), spare DDCU (E), forward avionics umbilicals for Destiny (F) and 2 MBSUs (G) SIDE 4: Aft radiator (H), and Segment to Segment Jumpers (I) on side 3 and Port. SIDE 5: Aft struts (J) and Aft tray or Rat s Nest door (K) SIDE 6: Forward struts (L), Module to Truss Structure attach system (M) and 2 MBSUs (N).
5 Starboard Side: showing the Airlock Spur. Port Side: showing the spare DDCU, EVA tools and Segment to Segment Jumpers.
6 Building the S0 truss payload bay version (simple build) For the Payload bay version model, an optional simple S0 truss was designed. Because it will be displayed in the Shuttle s payload bay, it s not important to show the interior of Side 1. To make it more realistic, the red arrow shows the inside of the Aft tray or Rat s nest section. This photo shows how is the inside after gluing the rectangular Aft tray section. Look again at photo on top.
7 Once the whole structure is built, then glue the Mobile Transporter railing section on top of SIDE 1. After this step is done, then it s very simple just to glue the other elements onto the rest of the truss sides. Photos show the outside and inside of the Aft tray door, which is glued on top of the inside section of the Aft tray. (see photo on next page)
8 Photo shows detail of the Avionics Umbilicals for Destiny lab. Just glue each TOP to each BOTTOM, fold and glue onto SIDE 2. Refer to photos to know the exact location. NOTE: These umbilicals are assembled the same way for both scale models with the exception that for the space station versions, these are glued to Destiny.
9 When gluing these umbilicals, be careful not to glue on top of the 4 circles (black arrow). These are the station GPS antennas. The rectangular areas with an arrow indicate the location where the MBSU boxes are placed. Just match the direction of the arrow on the corresponding MBSU boxes before you glue. (see next photo)
10 Photo also shows where the Keel support and Drag link are glued (arrows) The Module to Truss structure attach system is glued on this photo as well.
11 Note the building steps to assemble the Module to Truss structure attach system. It applies for both scales. Glue on top of a white line in the gray area (arrow) EVA tools. For the 1:100 scale model, these are glued. These are the support triangular parts for the Segment to Segment Jumpers. This applies to both scales.
12 SEGMENT TO SEGMENT JUMPER CONFIGURATIONS This is the launch configuration for these jumpers. This is the way it looks when the model is placed on the payload bay and when the S0 truss is placed on top of Destiny for this mission only. Note there are 2 jumpers or cables on each side. There are a total of 4 jumpers. This is the configuration after the S0 is glued to the S1 truss (STS-112 mission). Note which cables are still seen on the S0 truss: on the left, it s the outer cable; and on the right or Port side, the inner cable remains. On mission STS-113 (P1 truss), there should be no cables left on the S0 truss.
13 Note the cover for the spare DDCU box. This is only for the payload bay version. Note the position of the Node 3 umbilical tray (future STS-130 mission) It is optional to glue it until STS-130 mission, if not do not glue it. As a reference point, match the tip of the trunnion with the tip of the Node 3 umbilical.
14 Assembly of the Node 2 umbilicals A These are the parts to build each of the Node 2 umbilical. This applies to both scales. Photo shows the 1:100 scale version.
15 This photo shows part A of the Node 2 umbilical. Notice that is folded inwards. The final product looks like the blue part from the photo below (arrow). The 1:144 scale version of the Node 2 umbilical is much simpler but follows the same steps.
16 These parts are used only during folded position. Note how the tip is twisted in an angle.
17 Note the position of the Node 2 umbilicals on the S0 truss for the payload bay version of the model for reference when gluing these parts. IMPORTANT: these umbilicals should not be glued to S0 after mission STS-120, because these will be glued to Node 2 module. Another element to glue is the EV-CPDS box (arrow). For the payload bay version is only a triangular box, but for the space station version a different part is used.
18 Building the S0 truss Space Station version S0 exterior The building steps are similar for both scales. Important to fold this section as photo shows.
19 S0 interior This is the inside of the S0 truss (draft 1:144 model). Similar for both scales. Match the triangular boxes following the direction of the arrows and glue them. These boxes are the same for both scales.
20 Now glue the Trailing Umbilical system cable reel on top and bottom. Optional details are the boxes drawn (black arrows). You can leave it as it is or build similar 3D boxes and glue on top of the drawings for more realism. (ONLY FOR 1:100 SCALE). This is the time to do this step otherwise it would be very difficult to glue the boxes once the S0 truss is finished. Finished model showing boxes inside.
21 Another detail is this opening only for the 1:100 scale model. This opening is covered by a part that is glued from inside of the truss.
22 This is one of the interior walls of the truss. Each wall is different in details. In order to correctly glue them in the truss, the side that has the 4 little golden marks should face forward (arrows), and the black area where the red arrow is will indicate that that corner points down.
23 Test model showing the interior walls placed in between the triangular boxes. Another view from inside of the truss. One can only imagine the complexity of the real truss.
24 Now glue this part (arrow) on the outer face matching the openings. Now build each one of the DDCU boxes (white box) and glue following the direction of the arrow to the darker box or boilerplate box. There are 3 sets of DDCU boxes.
25 This is where the 3 rd DDCU box is glued.
26 All 3 DDCU boxes in place. For the 1:100 scale version, both boxes are glued together to a rectangular base (arrow)
27 Draft model showing both the exterior and interior parts of the truss. Put glue on SIDE 4 and on the inside of the exterior opening.
28 Glue on top
29 Add these parts A and B. Closeup view Now the assembly of the Aft tray.
30 This section is the aft umbilical tray for the S0 truss. In the real truss, these are the connections between the S0 and the Z1 truss, and it s been known as the Rat s Nest. Assembly of the supports or struts This is one of the forward struts of the S0 truss. This is for the 1:144 model only. It s a very simple approach in the design.
31 Note location of the Drag links on the space station version model. Note the orientation and positioning of the struts.
32 Note the position of the aft struts on top of SIDE 5. Photo below shows how the struts are folded as tripods. TIP: Fold the strut as shown matching the shortest leg with the longest one. Then open the strut as a tripod element.
33 Also note the location of the keel triangular supports on the Starboard side of the S0 truss for the space station version only.
34 A different approach in the design was done for the 1:100 scale version struts.
35 Building the space station First build the Avionics umbilicals for Destiny lab in order to place the S0 truss on top of Destiny. Note location of the Starboard and Port connector panels for the Avionics umbilicals for Destiny. (red arrows)
36 First glue the Mobile to Truss structure attach system to the Lab Cradle on top of Destiny (red arrow). Second, glue each of the Avionics umbilicals on each side of Destiny (yellow arrows) Third, glue the tip of each umbilical to each connector panels on S0 (light blue arrows) Closeup view
37 Now place and glue each of the forward struts (V parts) The S0 truss needs to be straight. Then start gluing the aft struts. Photo shows a draft version of one of the struts.
38 A view from the Port side showing a draft version of the aft struts. In general, the struts need to be glued as a tripod converging onto a small gray area on the aft section of Destiny (arrow) Smallest strut 2- Medium strut 3- Longest strut
39 Building the Airlock Spur Note location where the Airlock Spur is glued to the S0 truss. (red arrow) The tip of the Airlock Spur is bent 90 degrees inwards and glued to a tiny black dot at the end of a handrail on the Quest airlock (blue arrow). Note that the handrail is at the level of the NASA logo on Quest.
40
41 Umbilicals for Node 2 (post mission STS-120) The Node 2 umbilical is actually glued on top of the Destiny umbilical. Note where both ends are glued.
42 Note the upward orientation of the umbilical on each side. Adding the EV-CPDS box
43 Building the Mobile Transporter (1:100 model shown) TIP: Leave the white areas in order to cut the inner part.
44 Place the interior walls. Place the 4 triangular supports. The Grapple Bar is glued perpendicularly on top of the middle wall.
45
46 Note position of the radiator and the small box in front of the railcar.
47 This railcar model was not designed to be glued to S0 s Side 1 face. Instead, the 2 flaps shown here will attach the railcar to the truss. Note the location of the other boxes. The 1:144 model is a simple box and has no inner walls.
48 REFERENCE PHOTOS Note location of KU-band antenna that is glued on the tab from the right payload bay door.
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50
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52 Enjoy!
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