Card Model Building Instructions for: Saturn Rocket SA-1, SA-2, & SA-3 Missions Carl Hewlett March 4, 2007 1st A look at the Mission History: SA-1 Unmanned Mission 1961 October 27 - 15:06 GMT - Launch Site: Cape Canaveral. Launch Complex: LC34. Launch Vehicle: Saturn I. Model: Saturn C-1. LV Configuration: Saturn C-1 SA-1. * Test mission Nation: USA. Program: Apollo. Agency: NASA. Apogee: 136 km (84 mi). Largest known rocket launch to date, the Saturn I 1st stage booster, successful on first test flight from Atlantic Missile Range. With its eight clustered engines developing almost 1.3 million pounds of thrust at launch, the Saturn (SA-1) hurled waterfilled dummy upper stages to an altitude of 84.8 miles and 214.7 miles down range. In a postlaunch statement, Administrator Webb said: "The flight today was a splendid demonstration of the strength of our national space program and an important milestone in the buildup of our national capacity to launch heavy payloads necessary to carry out the program projected by President Kennedy on May 25.". SA-2 Unmanned Mission 1962 April 25 - 14:00 GMT - Launch Site: Cape Canaveral. Launch Complex: LC34. Launch Vehicle: Saturn I. Model: Saturn C-1. LV Configuration: Saturn C-1 SA-2. * Test mission Nation: USA. Class: Earth. Type: Atmosphere. Spacecraft: Highwater. Agency: NASA. Apogee: 145 km (90 mi). Second suborbital test of Saturn I. The Saturn SA-2 first stage booster was launched successfully from Cape Canaveral. The rocket was blown up intentionally and on schedule about 2.5 minutes after liftoff at an altitude of 65 miles, dumping the water ballast from the dummy second and third stages into the upper atmosphere. The experiment, Project Highwater, produced a massive ice cloud and lightning-like effects. The eight clustered H-1 engines in the first stage produced 1.3 million pounds of thrust and the maximum speed attained by the booster was 3,750 miles per hour. Modifications to decrease the slight fuel sloshing encountered near the end of the previous flight test were successful. SA-3 Unmanned Mission 1962 November 16 - 17:45 GMT - Launch Site: Cape Canaveral. Launch Complex: LC34. Launch Vehicle: Saturn I. Model: Saturn C-1. LV Configuration: Saturn C-1 SA-3. * Test mission Nation: USA. Class: Earth. Type: Atmosphere. Spacecraft: Highwater. Agency: NASA. Apogee: 167 km (103 mi). Third suborbital test of Saturn I. Saturn-Apollo 3 (Saturn C-1, later called Saturn I) was launched from the Atlantic Missile Range. Upper stages of the launch vehicle were filled with 23000 gallons of water to simulate the weight of live stages. At its peak altitude of 167 kilometers (104 miles), four minutes 53 seconds after launch, the rocket was detonated by explosives upon command from earth. The water was released into the ionosphere, forming a massive cloud of ice particles several miles in diameter. By this experiment, known as "Project Highwater," scientists had hoped to obtain data on atmospheric physics, but poor telemetry made the results questionable. The flight was the third straight success for the Saturn C-1 and the first with maximum fuel on board. You will need the following items: 1. PDF reader software 2. Computer Printer, (Color), with 8 ½”x11” media carriage 3. 8 ½”x11” bond copy paper 4. 8 ½”x11” card stock paper 5. Clear drying PVA Glue 6. Clear drying Glue Stick 7. Hobby Knife 8. scissors 9. Straight edge, (For cutting guide). Prep. For build by doing the following steps: 1. Plot/print the Parts PDF file. 2. Plot with fit to page turned off. 3. To make Model 1:96th Scale Plot/print pages reduced by 25%. 4. Cut parts out on a cutting surface, (i.e. cutting board). Steps for Build: 1. Cut out parts 1 & 2. Glue part 1 to 2. Roll, fit, and glue part 2 into a cone. 2. Cut out Part 5 & 6. Glue part 5 to 6. Roll, fit, and glue part 6 into a cylinder. 3. Laminate part 14 & 15 to heavy card stock media, (I use empty cereal boxes), and cut out. 4. Cut out and score parts 3 & 4. Roll both parts into cone shape. Glue to inner walls of cylinder 6, (Top and bottom), leaving feathered tabs exsposed. 5. Glue small black bead into peak of cone 2. Fit parts 14 & 15 into cylinder 6, (flushing to glue flange edge of parts 3 & 4, (Glue in place)). 6. Fit Cone 2 to top of cylinder 6. Glue into place. 7. Cut out parts 7 & 8. Glue part 7 to 8. Roll, fit, and glue part 8 into a cone. 8. Fit cone 8 to bottom of cylinder 6. Glue into place. 9. Cut out and score parts 9, 10, & 11. Glue part 9 to part 11. Roll, fit, and glue part 11 into a cylinder. 10. Roll part 10 into a cylinder. Fit into/inside the top of part 11 cylinder. Glue into place leaving glue tabs exsposed. 11. Laminate parts 12 & 13 to heavy card stock media. Cut them out. 12. Insert parts 12 & 13 into part 11 cylinder. Flush 12 to bottom edge of part 10, (part 13 flush to bottom of cylinder), Glue in place. 13. Laminate parts 16, 17, 18, & 19 to heavy card stock media, (Cut them out, (Set aside for now)). 14. Make sure You have printed 4 copies of page 5. Cut out parts 20 & 21. Roll, fit, and glue, into cylinders. Set aside. 15. Cut out parts 22 & 23. Glue 22 to 23. Roll, fit, and glue, into a cylinder. 16. Glue part 16 into top of part 23 cylinder. Glue part 17 into bottom of part 23 cylinder, (End with extra line 2” from end). 17. Slide part 18 over the top end of part 23 cylinder, Down to black line. Do not glue. 18. Slide part 19 over the bottom end of part 23 cylinder, Down to black line. Do not glue. 19. Fit part 21 cylinders to all four points of the compass. Set assembly on a level flat surface. Spot glue to tack all cylinders together. Set aside to dry for a hour or so. 20. Install part 20 cylinders, (Infill), and glue in place. Let dry for a hour or so. 21. Laminate part 24c & 26, to heavy card media. Cut out. Next cut out 24b, glue to bottom of 26, (Cut out center), then glue 24c to top of 26. 22. Cut out and score parts 25 & 25a. Glue part 25a to 25. Roll, fit, and glue part 25 into a cylinder. 23. Cut out parts 24 and 24a. Glue part 24a to 24. Roll fit, and glue part 24 into a cone. 22. Insert part 24b/24c/26 assembly, into part 25 cylinder. Move flush to top of checkered pattern on outside. Glue into place. 23. Fit part 24 cone to glue tabs of part 25 cylinder. Glue into place, (Put assembly aside for now). 24. Cut out and score parts 27 & 29. Glue part 27 to 29. 25. Cut out and score parts 28 & 30. Glue part 28 to 30. 26. Glue Part 29 to 30. Flush top part 30, (tab end), to bottom of part 29, (non-tab end). 27. Roll, fit, and glue, combined part 29/30, into a cylinder, (Do not fold engine fairings yet). 28. Laminate part 31 & 32 to heavy card media. Cut out, (Leave black support lines in part 32). 29. Cut out and score, parts 46 & 47. Glue part 47 to 46. Roll, fit, and glue, part 46 into a cylinder. 30. Fit part 31 to bottom of part 29/30 cylinder. Shape 29/30 cylinder, to fit profile of part 31, (Tack glue as You fit, (Final glue bead after fit)). 31. Place part 46 cylinder into part 29/30 cylinder. Tack glue to inner walls of part 29/30 cylinder, (At indented contact points). 32. Glue and fold engine fairing tabs in now. 33. Fit part 32 to top part 29/30 cylinder, (Repeat steps called out in item #30 to fit and glue in place, (Cut black supports out after glue is dry). 34. Fit the full Bottom Fairing assembly to the bottom complete tank assembly, (Glue into place). 35. Cut out part 42, (Bottom fairing). Slide over top of tank assembly. Fit to top of bottom assembly. Glue in place, (Trim to flush after glue is dry). 36. Fit and glue Part 24/25 assembly to top of tank assembly. 37. Cut out parts 34 & 35. Roll and glue into cones. 38. Cut out part 33. Place glue inside of parts 34 & 35. Roll Part 33 with printed side inside and place inside of parts 34 & 35. 39. Laminate part 36 to heavy card stock media. Cut out and glue with printed side facing the inside of part 34 & 35 engine assemblies. 40. Glue parts 34 & 35 assemblies to part 31 with part 34 on the outboard points. 41. Cut out parts 43, 44, & 45. Roll fit and glue 43 & 45 into cylinders. Connect 43 & 45 together with a wrap of part 44. Put a dab of glue in the open end of part 43. Pinch flat an hold. 42. Glue 43/44/45 assembly to the grey circle on part 31 to the side of each outboard engine cone, (part 45 round end). Next glue the flat end to side of engine cone. 43. Cut out, score, fold, and glue part 37 into a assembly. Next glue it into the void between the center group of engine cones. You may want to install this part, (and group the center cones into a assembly), before You glue the center cones in place. 44. Cut out parts, 38 & 39. Roll fit an glue into cylinders. You may want to print these parts on standard bond copy paper, (for easy of rolling). Glue into place on locations marked on side of outboard first stage tanks. Trim to profile at bottom tank skirt. 45. Misc. Parts 40, 41, & 48 thru 54 should be cut scored and installed as per attached build pictures, (Part 48 thru 54 are for SA-3 optional build only). Enjoy Your finished model. Carl