Instrument Truss:
I'm back! Did some work at the weekend ...
I previously posted a picture of the instrument truss as printed from the file. The gaps between the latticework are filled in with grey to reduce the effect.
However, having been advised by Zathros (
I listen to you Zathros

) to strengthen other trusses and thin support bracing with superglue, I decided to experiment with this and see if I could construct it as a proper hollowed out lattice.
So I cut out the 48 small triangles and other bits at the ends (having scored and folded along the length before I started cutting - knowing what remains would be very flimsy). 4 hours work, with only one slip and cut too far through one of the truss sections - repairable with glue later.




Then time spent blacking all the edges, tidying up here and there (the card started to delaminate at the fold lines in a few places because the width is so narrow, less than 0.5mm in some places); then trying to fold it as much as possible before gluing (it has to be superglued in the final shape because trying to score and fold once superglued is very difficult). 2 hours work.
Then application of superglue down the length to make the box shape, one side at a time. I used Starbond EM-02 which is superglue with the consistency of water - it runs everywhere, bonds almost instantly, but is really easy to cover an entire face of this just by putting a few drops on a bit of greaseproof paper and rubbing the latticework over it. It's expensive here in the UK but worth it for certain applications.
Then applying normal superglue to the inside faces through the holes with a cocktail stick.
All the superglues I've used dry rather shiny or at least satin, so then needed to paint all surfaces, inside and out, with Tamiya Flat Black, and then a final coat of Vallejo Matt Varnish. Another 2-3 hours work.
I even managed to keep it relatively square on looking down the middle too (easier with the eye than a camera!)
It does make me think ... can I succeed at doing the same with the Magnetometer boom/truss - triangular cross section, 25cm long, 240 triangles to cut out ...