Need to keep the thread up to date with progress ...
RTG Truss:
I'm back trying to solve/interpret the instructions for the RTG truss. I'm going to show a fair bit of detail and explanation in case anyone else is building this model. However, I must say that although I think I've found a solution that works, it might still be wrong! I would love to hear from anyone who has built this before to find out what their experience of this aspect was like.
Here's the part of the printed sheet for reference. The one on the right is the large (inner) mounting truss and is glued to the side of the bus/main unit. The one on the left is the smaller outer mounting truss and connects to the RTG. I've shown which is which with the blue arrows.
Also note where it says the bottom of each one is. Each part is basically folded together, so "bottom" helps to know which half of each is facing up and which half is facing down.
The difficulty arise in working out how to glue to two of these together once they're folded. The upper diagram is a side-on view of how these bits go together. It's a bit ambiguous because the large truss also includes that inner folding up half-circle piece which on the photos in the instructions shows the MAG sitting on that. But you'll discover that there's an optional MAG canister mount which is shown in the diagram. The side view also shows you what angle you should be aiming for when gluing the trusses together, so that the RTG ends up horizontal.
After having failed in my first attempt, I printed up a double size version to experiment with. It's much easier being this large. On the left is the smaller/outer truss (it's actually upside down), on the right is the larger/inner one. I coloured the underside of the outer one red to make it easier to see when they're joined together, which bits are connected.
The photo below shows the two pieces folded roughly into their final angles-ish. The outer one on the left has been turned over from the photo above, so it's now the right way up. Also I glued the triangle together which you wouldn't do until you glue the RTG onto it, but I had to do it to make it stay folded at that angle for this illustration.
The small bent up flap on the left piece is going underneath the MAG canister mount on the right one.
Here it is after gluing the two together. My confusion lay in the instructions where it says "Glue the centre tab
over the fold on the inner truss". This is consistent with the diagram at the top of this post, where you can see the tab on the left hand side of the outer truss horizontal and overlapping the left hand edge of the inner truss, with the optional MAG mount on top of that.
In mine below, you can see that the MAG mount blocks you from gluing the tab over the fold. It's in the way. So I glued the tab underneath the MAG mount instead. If that MAG canister mount wasn't there, you could fold it over the top instead. When I've done it all properly and been able to work out how the optional MAG canister mount goes, it may be clearer. Perhaps the instructions were for if you've removed the MAG mount in preparation for using the optional one, but in all the photos in the instructions pdf (and the diagram at the top of this post), this MAG mount is still there and the optional one isn't used. Perhaps it was an improvement made after finishing the design.
Anyway, onwards! Here's the other side to show those flaps at the sides being folded inside the lower arms of the inner truss - the angle of the flaps will help the assembly sit at the right angle.
So onto having a go for real, at the smaller scale of the actual model ... Here are the two pieces folded, coloured black and cut. Here's the larger/inner truss in detail. The needle points to the tab surface that will be glued (the "hairy" bits will be cleaned off before being glued. It's amazing how many flaws a phone camera picks up that you almost can't see with the naked eye!)
And the smaller/outer one.
Before going any further, I put superglue on the 8 legs (4 on each truss) to strengthen them, being careful not to encroach anywhere where there will be folding to do. After finishing the gluing of this assembly I will coat the other side and anywhere I can reach, and then paint matt varnish over the lot for maximum rigidity.
First the inner truss is secured to the main bus at 3 points.
The angle is close enough to the side on illustration.
When gluing the two trusses together, the diagram can be used to help get the angle of the outer one right. The aim is that when the far ends of that (the big triangle to the little tab), the surface will be vertical so when the RTG is glued to it, the RTG sits horizontally. There's a bit of flexibility here because you can alter the final angle depending on how much of the upper tab you fold and glue to the big triangle folded up from the lower side.
As worked out with the double size version previously, the outer truss centre tab is glued to the mid-frame cross piece on the outside underside of the MAG cannister mount. After the tab is glued, then fold the side tabs down and round the inner truss lower legs to form the angle and glued them into place. This locks in the final angle of the two trusses together somewhat.



Both trusses in place. I glued the RTG to the triangle first, and then glued the triangle and upper tab together. It seemed easier to get the final angle correct looking at the RTG and what angle it's sitting at, rather trying to get the small vertical surface of the triangle on the end of the truss. The weight of the RTG caused a bit of sag on the whole truss, so best to take that weight into account before gluing it all up together. I got the angle a bit wrong and my triangle piece delaminated, so I just filled it in with PVA glue in the right position until I built it up to the surface. That's why the triangle section looks a little thick and wedge-shaped side on. Did the job though.
Once all the pieces were together I coated the remainder of the truss parts, including all the angles with EM-02 superglue which absorbs into the card really well, forming a strong and sturdy structure. Applied a coat of Flat Black paint (still trying on one of the struts) and if needed, a coat of the Matt Varnish to fully remove the CA glue's shine.
Phew, another section completed