To follow up on our discussion a few months ago, I finished a test part
using 0.016 inch 2024-T4 sheet over stringers for a 6 inch OD fuselage.
It turned out pretty nice and is plenty stiff enough. The slip roll I
had access to at the Dallas Makerspace had rollers too large so I ended
up rolling it by hand over a piece of 1.5 inch schedule 40 PVC pipe. It
wasn't completely round after rolling but it was better than trying to
bend a flat sheet at assembly time. I made some drill jigs for the skin
and stringers and used a single #30 slip fit bushing to drill the
holes. I probably don't need flush fasteners for this rocket but I
wanted to try it anyway so I dimpled the skin and then used a
countersink on the holes in the stringer to accommodate the skin. The
fasteners were AACS-04-02 blind rivets. I plan to use this arrangement
for the tank sections where I don't need access and then use nutplates
for the other sections.
Photos:
http://www.watzlavick.com/robert/rocket/rocket1/photos/dsc_7257m.jpg
http://www.watzlavick.com/robert/rocket/rocket1/photos/dsc_7253m.jpg
http://www.watzlavick.com/robert/rocket/rocket1/photos/dsc_7251m.jpg
http://www.watzlavick.com/robert/rocket/rocket1/photos/dsc_7248m.jpg
There's some more detail on the main page.
-Bob
