I have loved model rockets since I was a kid, but instead of building from kits I prefer to make funky ones from scratch. About a year ago, I got the idea to make a dual-engine model rocket in the shape of Iron Man. The idea presented a lot of unique challenges--which I've enjoyed working on--but this was one project I was happy to finally get out of the way.
I spent many nights lying awake trying to figure out how to make a man-shaped model rocket flight-stable, how and what to make him out of (to keep the weight down), how to construct the parachute deployment system, how to mount him onto a launch rod, what kind of launcher I would have to make, and on and on. I resolved most of the issues, and I'll show you how all of these ideas came together.
There were plenty of missteps and failures along the way throughout this project, but I've cut most of that out in order to keep this as straight-forward as possible. Please excuse the shoddiness of the exterior details on the finished rocket. This is less about the actual Iron Man character, and more about my journey and the process of trying to make and fly a crazy man-shaped rocket. In the end, you'll see that I had mixed results with this project.
I began by making the head, which I figured would be the hardest part. You can see the details of that here.
I spent many nights lying awake trying to figure out how to make a man-shaped model rocket flight-stable, how and what to make him out of (to keep the weight down), how to construct the parachute deployment system, how to mount him onto a launch rod, what kind of launcher I would have to make, and on and on. I resolved most of the issues, and I'll show you how all of these ideas came together.
There were plenty of missteps and failures along the way throughout this project, but I've cut most of that out in order to keep this as straight-forward as possible. Please excuse the shoddiness of the exterior details on the finished rocket. This is less about the actual Iron Man character, and more about my journey and the process of trying to make and fly a crazy man-shaped rocket. In the end, you'll see that I had mixed results with this project.
I began by making the head, which I figured would be the hardest part. You can see the details of that here.
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I laid out a design for the body by copying details from photos of Iron Man and an Iron Man toy I borrowed from a friend. If you're feeling ambitious, I've included a PDF with the front and side lay-outs that I created. The total height of the finished rocket is 36 inches.
I ordered rocket supplies from apogeerockets.com, which has been a very nice company to work with. I ordered a bunch of 24mm tubes (which hold D- and E-size Estes model rocket engines), some tube couplers, engine block rings, launch lugs, and kevlar cord.
My first attempt at making the body was with layers of pink insulation foam glued together with the rocket tube structure sandwiched inside. I used a sharp knife to carve out the body shape, which was tedious and messy. In the end it weighed too much to use and I had miscalculated the proportions, so the head which I had already finished was too small for the body. After plenty of cursing, the pink foam body ended up in the trash... in very tiny pieces. I re-sized the lay-out, and waited a few months till I was ready to work on it again.
For my second attempt, I decided to build the body up using foam board (1/4-inch foam sandwiched between paper). This proved to work very nicely for making a lightweight skeletal-type structure, but led to some difficulties in covering.
I ordered rocket supplies from apogeerockets.com, which has been a very nice company to work with. I ordered a bunch of 24mm tubes (which hold D- and E-size Estes model rocket engines), some tube couplers, engine block rings, launch lugs, and kevlar cord.
My first attempt at making the body was with layers of pink insulation foam glued together with the rocket tube structure sandwiched inside. I used a sharp knife to carve out the body shape, which was tedious and messy. In the end it weighed too much to use and I had miscalculated the proportions, so the head which I had already finished was too small for the body. After plenty of cursing, the pink foam body ended up in the trash... in very tiny pieces. I re-sized the lay-out, and waited a few months till I was ready to work on it again.
For my second attempt, I decided to build the body up using foam board (1/4-inch foam sandwiched between paper). This proved to work very nicely for making a lightweight skeletal-type structure, but led to some difficulties in covering.
ironman body template.pdf(540x720) 408 KB
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We are going to be the Avengers for Halloween and Joey is going to be Iron Man. Can you whip up some costumes for us?? Hahaha. Seriously though...store bought is embarrassing but Joey has no time to help with law school. What do you charge for custom Halloween costumes?
Suzy
(Ha ha. Let's chat in private. Long time no see!)
The main pic is amazing !
I'll add this to the list for the next version!
YOUTUBE.COM RCSUPERHERO
WEBSITE IS RCSUPERHERO.COM
ITS A 6'3" FULL SCALE FLYING MAN !!!!!!!!!
VERTICAL TAKE OFF LIKE THIS ONE TOO AND SEMI-AEROBATIC
A few people have asked about the parachute. I've got some more information on the parachute spread throughout the comments section.
I did have a lot of time invested in that head. The problem is my next one may be a smaller scale to use up some smaller rocket tubes and engines that I've got lying around. So a new head will need to be made as well.
...We'll see if I ever get around to it. No promises!
There are some really great projects in this contest. We'll see how it goes!
The video is quite bad. The photo is much cooler than the actual video.
I knew the weight was such that he would never gain enough altitude to have time for a parachute to deploy. In the video, you see him come crashing down, a couple seconds pass, and then the motors shoot their ejection charge, which is what pushes the parachute out. So it wouldn't have made a difference anyway. That's the logical reason.
The emotional reason is this: this project offered a lot of unique new challenges for me (which is what I look for in a project), but I was generally unhappy with the results. So after months of thinking about it and working on different aspects of it and having it drive me nuts, I was really looking forward to watching it crash. Kind of crazy, huh?
Very nice!! I love this idea.
I really like that you are in a "toys building" mode like me, I should definitly try this :D Although mine will probably have explosives packed in his head and body. I just like to see them explode mid-air ^^
You got my vote in the contest buddy :)
Model rocketry was a blast growing up as a kid spurred on by the real great space race. Too bad it has become costly and prohibited to do in many places. Maybe add on clear plastic stablizing fins next time. My creation was a "Little Joe" Saturn V command capsule test booster made from box cardboard. It must have turned out about a few pounds. It crashed and burned but the slow spiral from the first time I used a D engine was the best.
In the photo of the underside of his feet in the introduction, you can see the holes next to the rocket tubes where I had sleeves in place to hold dowels which would extend below each leg to which the fins would be attached.