ISD KRAKEN - Aluminum Work Update 1
After several iterations of the design, with the size of the ship growing by the year, it was finally time to send it to the laser cutter and bender. I would have loved to do the work myself but I do not have access to any laser or large scale bender anymore. Several companies informed me that they couldnt bend the 254 cm aluminum plates. Guess aluminum work at this size doesnt happen very much.
Transport of the parts had to be done with a courier and had to count out the parts in front of my house. Luckely it was good weather!
After moving all the parts up 3 stairs the enormity actually set in. I have two rooms on the top floor of my house. A office/clean room and a dirty room with printers and tools. Had to move all the fitness equipment out of the office to make space for this Monster!
I tested out the male/female connections of the ribs. It all fitted perfectly, maybe a little bit to perfectly and had to grind down the male parts for the welding to take hold.
The ship is more fragile then you think. Welding the tube to the alumium bottom hull and then transporting it to the US with all the bumps and shakes will probably cause the aluminum to crack or even tear itself apart. Thats why I designed a 3mm steel plate (the dark grey plate) that will form a harnas over almost the entire length (belly) of the ship. Also welding a steel tube to a steel plate is much easier then to a aluminum plate.
I cannot get the stand welded just yet as i need to perform a COG (Center of Gravity) analysis with the PC hardware and Liquids installed for a good indication of the final weight distribution.
Also planning on integrating a Homokinetic Coupling from the drive axle of a landrover into the tube. This will allow the ship to pitch , bank and rotate on the stand.
That will complicate the entire weight big time! More on that later.
Used a board from my retro machines collection to test out the motherboard tray location and space for it.
Its such a huge ship that even a E-ATX board would look like a ITX !
I was wondering if i could place two reservoirs in the PC cabin as the ship is meant to be able to pitch and bank on the stand. This would mean a potential liquid displacement that could cause the one of the pump to run dry. By using two reservoirs banking the ship left or right would cause additional waterpressure on one the reservoirs thereby improving the flow and preventing stalling the flow.
After the welder came by and took the ship for a few days it returned and i had to do all the inspections again to make sure the aluminum wasnt warped by the heat.
Luckely it wasnt (well i payed for a good welder ) just one minor spot where the heat of the weld for a rib caused some very local warping (maybe 1 or 2mm). This is easily fixed as the ship will be covered in styrene and printed parts covering up any affected section.
Tested out the designs for the radiator bay also by mounting several radiators. All the holes were in the right prositions with 1 mm seperating the radiators themselves.
With the top hull on the ship its a great view of the bay itself.
The bay will be extended to the rear with a custom designed meshed aluminum grill holding the 3Dprinted engines in place.
The engine bay will be a tricky sub project but will be a big eye catcher when its done.
The airflow will be as followed. The clean air gets sucked in through the 125 mm tube stand connected to the stabiliser plate on the ground. The air will come in below the motherboard tray and will be trusted outward through the engine bay grill. This is why selection of the 3d filament materials is such a big thing. More on airflow, thermal performance and the selection of the right materials will be written later.
And thats how we got to this point. The two ships.
If you think about doing this yourself please be aware that the aluminum plates, bending, welding and transport set us back about 3000 euro. That is without all the hours for design, preparation and negotiating prices!
So gratefull to Spacec to get the opportunity to build these puppies!
If you have any ideas or remarks, let us know in the comments!