A door’s hinges are arguably its most important pieces. After all, a door without hinges is just, well, a wall. Or a bulkhead, if we’re talking about a hingeless hatch on a spacecraft.
And so the assignment for creating hinges for Progress Egress, the celebration of the 50th anniversary of the Apollo 11 landing by creating a replica of the command module hatch, went to [Jimmy DiResta]. The hinges were complex linkages that were designed to not only handle the 225 pound (102 kg) hatch on the launch pad, but to allow extended extravehicular activity (EVA) while en route to the Moon. [Jimmy], a multimedia maker, is just as likely to turn metal as he is to work in wood, and his hinges are a study of 1960s aerospace engineering rendered in ipe, and extremely hard and dense tropical hardwood, and brass.
[Jimmy]’s build started with a full-size 3D-printed model of the hinge, a move that paid off as the prints acted both as templates for machining the wood components and as test jigs to make sure everything would articulate properly. Sheet brass was bent and soldered into the hinge brackets, while brass rod stock was turned on the lathe to simulate the hydraulic cylinder hinge stays of the original. The dark ipe and the brass work really well together, and should go nicely with [Fran Blanche]’s walnut and brass latch on the assembled hatch.
With [Adam Savage]’s final assembly of all the parts scheduled for Thursday the 18th, we’re down to the wire on this celebration of both Apollo and the maker movement that was at least in part born from it.
Note: the assembly started at 11:00 Eastern time, and there’s a live stream at https://airandspace.si.edu/events/project-egress-build.
Continue reading “Project Egress: The Hinges”
Put yourself in [This Old Tony]’s shoes: you get an email out of the blue asking you to take part in making a replica of a 50-year-old spacecraft. Would you believe it? He didn’t, at least not at first, but in the end it proved to be true enough that he made these two assemblies for Project Egress in his own unique style.
If you haven’t heard of Project Egress, check out our coverage of the initial announcement. The idea is to build a replica of the crew hatch from the Apollo 11 Command Module Columbia, as part of the 50th anniversary of the Apollo 11 landing next week. [Adam Savage] at Tested has enlisted 44 hackers and makers to help, spreading the work out among the group and letting everyone work in whatever materials and with whatever methods they feel like. [Old Tony], perhaps unsurprisingly, chose mainly Apollo-era dehydrated space-grade aluminum, machined using a combination of manual and CNC machining. We really like the finish he chose – a combination of sandblasting and manual distressing to give it a mission-worn look.
As for exactly what the parts themselves are, the best [Old Tony] could come up with to call them is a bracket and a bell crank. From the original hatch drawings, it looks like there were two bell cranks, which will transmit force around the hatch to the latches that [Fran Blanche], [Joel] and [Bob], and no doubt others have contributed to the build.
We’re eagerly anticipating the final assembly, to be executed by [Adam] live at the Smithsonian’s National Air and Space Museum on July 18. Project Egress is as much a celebration of the maker movement as it is a commemoration of Apollo, and we’re pleased that people will get a chance to see the fruits of the labors of all these hackers in so public a forum.
Continue reading “Project Egress: A Bracket And A Bell Crank For The Latches”
Every door needs a handle, even – especially – the door of a spaceship. And [Paul] from “Paul’s Garage” got the nod to fabricate the handle for the Apollo 11 Command Module hatch being built as part of Project Egress.
For those not familiar with Project Egress, it’s a celebration of the 50th anniversary of the first Moon landing that aims to recreate an important artifact from the mission: the Unified Crew Hatch, or UCH, from the Apollo 11 Command Module Columbia. Forty-four makers from various disciplines have been tasked with making the various pieces of the UCH, and each one is free to use whatever materials and methods he or she wants. [Paul] chose what will probably turn out to be the consensus material – aluminum – and decided to play to his strengths by casting the part.
The handle itself is a chunky affair, as one would expect from something designed to be handled by an astronaut. [Paul] started with a 3D-printed version of the handle and created a two-piece mold in casting sand. The original part was probably machined, which meant that it didn’t have the draft angle that cast parts are supposed to have to make removal from the molding medium easier. [Paul] lucked out and got a perfect mold, and a perfect pour from silicon aluminum to boot. All the casting needed was a little cleanup and some holes to bolt it to the door.
[Paul]’s handle will get shipped to the Smithsonian along with the other parts, like [Fran Blanche]’s latch assembly, so that [Adam] can assemble the hatch live during the 50th-anniversary celebration later this month. Stay tuned for more Project Egress coverage as the parts keep rolling in.
Continue reading “Project Egress: Casting The Hatch Handle”