Besides the honeycomb structure itself, the construction also consists of the rails that are responsible for the guidance of the missiles during launch. Most of the rails have retaining hooks made from heat treated spring steel to prevent the missiles from falling out. These hooks are riveted to the rails.
From the dimensions we got from the evaluation of the surviving specimen we were able create a Freecad model, from which we can take the correct measurement of the single parts of the honeycomb assembly. This is relatively time-consuming, but after a few trials we have a result we can work with.
Before the planking of the nose section will be continued, the rocket honeycomb is going to be built and made fit. This is by far not trivial, as we were not able to find any good drawings of this device. So we had no choice and had to take the dimensions from preserved original parts and to reverse-engineer the whole assembly. Apart from the honeycomb the Natter in the Smithsonian Institute in Washington there is still a dug up relic fragment in a German museum store. We have been lucky to get permission to examine the artifact and to take pics and dimensions. This took two days.
To avoid triple lamination, will continue with 3 mm plywood trials. We are aware that a lamination from 3 layers makes bending much easier and probably achieves also a higher strength . But tests have shown that applying the glue and pressing is also not very simple, due depending on the temperature the glue dries too fast and it's a more sophisticated pressing device is required. So, we tried again with simple methods. The new idea is to slowly pre-bend the plywood on a simple jig.
The wings and tails will be planked with curved 3 mm plywood. There are two possibilities. Either you laminate 3 layers of 1mm plywood or you try to bend the 3mm plywood to the right shape . First, we tried it with the 3mm plywood and got it well wet before bending. You see, the result was quite unsatisfying.
The main spars for the wings are manufactured in sandwich design. Advantage: Increased stiffness at low weight. Here occurs a deviation from the original: In order to make the transport much more easy we designed the wings in a way that they can be removed. Due to this, the wing main spar is cut in half.. At the original the main spar is designed as one piecee.