Rock On Structure Build 1 Rock On 2008

Rock. On! Structure Build 1 Rock. On! 2008

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Step 11: Staking AVR Wires -Stake the soldering location of the AVR wires on the AVR PCB as shown. 6 Rock. On! 2008

Structures Overview: - Open your structures kit and verify its contents. - ESD protection should be utilized during the entire building process! - Make sure anyone handling the hardware is protected from ESD damage. - If any issues arise raise your hand for assistance. 7 Rock. On! 2008

Structural Kit Overview: Nuts and Bolts Red M 3. 0 x 35 (4) Black M 3. 0 x 25 (4) Nylon spacers (24) Light Green M 2. 5 x 10 (3) M 3. 0 nuts (16) Red M 2. 0 x 10 (2) M 2. 5 nuts( 3) M 2. 0 nuts (2) Purple M 3. 0 x 10 (2) Light Blue M 3. 0 x 10 (4) Light Green M 3. 0 x 10 (2) *Bolts and nut are 1: 1 scale 8 Rock. On! 2008

Structural Kit Overview: Brackets ‘L’ Battery bracket (1) G-Switch bracket (1) Z Accelerometer bracket (1) 9 Rock. On! 2008

Structural Kit Overview: Adding Electrical Tape Leaving the holes free, add electrical tape to the Z accelerometer on the three-hole piece. Z Accelerometer bracket 10 Rock. On! 2008

Structural Kit Overview: Parts from other kits G-switch (1) Blue RBF Wire (several feet) Red LED with connector (1) Green LED (1) 11 Rock. On! 2008

Structural Kit Overview: Parts from other kits G-switch (1) Blue RBF Wire (several feet) Red LED with connector (1) Green LED (1) 12 Rock. On! 2008

Structural Kit Overview: Parts from other kits Geiger Board (1) AVR Board (1) Z Accelerometer Board (1) 13 Rock. On! 2008

Structural Kit Overview: Tools Screwdriver Set Small Wrench Needle Nose Pliers 14 Rock. On! 2008

Structural Kit: Mounting Plate Geiger Board (red) G-Switch (purple) Z Acc (green) AVR (black) Batteries (blue) 15 Rock. On! 2008

Let’s Start Building! 16 Rock. On! 2008

Structural Kit: Completed Plate 17 Rock. On! 2008

Step 1: AVR Mounting - Find the M 3. 0 x 25 Black bolts for the AVR. - Mount the AVR in the orientation shown on the following slide using nylon spacers. - The nylon spacers will be above and below the board as shown. - AVR holes are colored black on the mounting plate. - Hand tighten with an M 3. 0 nut followed by a final ½ turn using the wrench and screwdriver. 18 Rock. On! 2008

Step 1: AVR Mounting ***Note the orientation of the AVR*** x 4 for all holes on the AVR 19 Rock. On! 2008

Step 1: AVR Mounting [Before] Geiger Board AVR G-Switch Z Acc Batteries 20 Rock. On! 2008

Step 1: AVR Mounting [After] 21 Rock. On! 2008

Step 1: AVR Mounting [After close-up] Top Down View Side View Bottom-Up View 22 Rock. On! 2008

Step 2: Z Accelerometer Mounting - Find the M 3. 0 x 10 green bolts for the Z accelerometer bracket. - Mount the Z accelerometer bracket as shown. - Make sure the electrical tape is oriented on the correct side of the Z accelerometer bracket. - Z accelerometer holes are colored green on the mounting plate. - Hand tighten with an M 3. 0 nut followed by a final ½ turn using the wrench and screwdriver. 23 Rock. On! 2008

Step 2: Z Accelerometer Mounting [Before] 24 Rock. On! 2008

Step 2: Z Accelerometer Mounting 25 Rock. On! 2008

Step 2: Z Accelerometer Mounting [after] 26 Rock. On! 2008

Step 2: Z Accelerometer Mounting [after close-up] Bottom View Top View 27 Rock. On! 2008

Step 3: Z Accelerometer Mounting - Find the M 2. 5 x 10 Light Green bolts for the Z accelerometer. - Mount the Z accelerometer as shown. - Hand tighten with an M 2. 5 nut followed by a final ½ turn using the pliers and screwdriver. - *** Use three nylon washers between the bracket and PCB of the accelerometer. *** - Hand tighten with an M 3. 0 nut followed by a final ½ turn using the wrench and screwdriver. 28 Rock. On! 2008

Step 3: Z Accelerometer Mounting [before] 29 Rock. On! 2008

Step 3: Z Accelerometer Mounting 30 Rock. On! 2008

Step 3: Z Accelerometer Mounting [after] 31 Rock. On! 2008

Step 3: Z Accelerometer Mounting [after close-up] Behind View Front View Caution! These are the leads in question. Top Down View (note the washers used for spacing) Rock. On! 2008 32

Step 4: Z Accelerometer Connection - Connect the four pin header to the ‘Z main’ location on the AVR as shown. - Make sure you connect Red to “+” and Black to “-”. 33 Rock. On! 2008

Structures Overview: - Open your structures kit and verify its contents. - ESD protection should be utilized during the entire building process! - Make sure anyone handling the hardware is protected from ESD damage. - If any issues arise raise your hand for assistance. 34 Rock. On! 2008

Step 5: Geiger Counter Mounting - Using hot glue, stake down the red wire leading off the Geiger counter to the Geiger PCB near the bend in the wire. 35 Rock. On! 2008

Step 5: Geiger Counter Mounting - Make sure the red Geiger wire is staked down before you mount the Geiger counter. - Using four nylon spacers and the Red M 3. 0 x 35 bolts mount the Geiger Board to the plate as shown. - Hand tighten with an M 3. 0 nut followed by a final ½ turn using the wrench and screwdriver. 36 Rock. On! 2008

Step 5: Geiger Counter Mounting Bottom View Side View 37 Rock. On! 2008

Step 6: Geiger Counter Connection - Connect the three pin header on the Geiger counter to the breadboard on the AVR as shown. Connect black to the black wire, red to the red wire as depicted. 38 Rock. On! 2008

Step 6: G Switch Bracket Mounting - Find the G Switch bracket and mount to the plate as shown. - The mounting bolts are two M 3. 0 x 10 colored purple. - The holes to be mounted are closest the bend in the ‘L’ bracket. - Finger tighten with an M 3. 0 nut followed by a final ½ turn using the wrench and screwdriver. 39 Rock. On! 2008

Step 6: G Switch Bracket Mounting [after] 40 Rock. On! 2008

Step 6: G Switch Bracket Mounting [after close-up] Bottom View Top View 41 Rock. On! 2008

Step 7: G Switch Mounting - Find the G Switch and mount to the G Switch bracket. - The mounting bolts are two M 2. 0 x 10 colored red. - Finger tighten the bolts with M 2. 0 nuts plus an additional ½ turn using the pliers and screwdriver. 42 Rock. On! 2008

Step 7: G Switch Mounting 43 Rock. On! 2008

Step 7: G Switch Mounting [After] 44 Rock. On! 2008

Step 7: G Switch Mounting [After Close-up] Front View Back View 45 Rock. On! 2008

Step 7: G Switch Mounting - Connect the G Switch header to the AVR board location labeled ‘Gswitch’. - Since there is no polarity to this shorting mechanism, the orientation of the wires does not matter. 46 Rock. On! 2008

Step 7: G Switch Mounting [After] 47 Rock. On! 2008

Step 8: Battery Bracket Mounting - Acquire Flight Batteries in your structures kit. - Find both battery brackets and mount to the plate as shown. - Mount all brackets using m 3. 0 x 10 bolts colored light blue. - Hand tighten with an M 3. 0 nut followed by a final ½ turn using the wrench. - Mount the ‘L’ bracket first pushing the batteries flush with it on the plate. 48 Rock. On! 2008

Step 8: Battery Bracket Mounting [Before] 49 Rock. On! 2008

Step 8: Battery Bracket Mounting 50 Rock. On! 2008

Step 8: Battery Bracket Mounting [After] - Orient the battery connectors to lead the extending wires to the left. 51 Rock. On! 2008

Step 8: Battery Bracket Mounting [After close-up] Top View Bottom View *Note flushness of batteries with ‘L’ bracket 52 Rock. On! 2008

Step 8: Battery Connection - Connect the header from the batteries to the ‘Power’ location on the PCB. - The header should be right next to the ‘RDY’ and ‘ON’ locations within the PCB. - **Note the Red lead from the battery should connect to the ‘+’ indication on the PCB. 53 Rock. On! 2008

Staking and Mounting 54 Rock. On! 2008

Step 1: Mounting the AVR - Slide some nylon threading underneath the AVR socket and tie down to the socket as shown. - The nylon should be tightly secured to the chip. Have a partner (who is also ESD protected) help you tie a tight knot. 55 Rock. On! 2008

Step 1: Mounting the AVR - Slide some nylon threading underneath the AVR socket and tie down to the socket as shown. - The nylon should be tightly secured to the chip. Have a partner (who is also ESD protected) help you tie a tight knot. 56 Rock. On! 2008

Step 1: Mounting the AVR 57 Rock. On! 2008

Step 2: Tying sensor wiring [plate overview] 58 Rock. On! 2008

Step 2: Bundling Wires - Each set of wires on the board should be bundled two or three times. - Use the nylon threading to bundle the wires together as shown. - Use a square knot to tie the nylon threading and trim the excess leaving an inch remaining. - USE CAUTION!! Don’t snip your wiring while doing this!!! 59 Rock. On! 2008

Step 2: Bundling Wires AVR Overview 60 Rock. On! 2008

Step 2: Bundling Wires Plate Overview 61 Rock. On! 2008

Step 3: Mounting Battery wires - Orient the battery wiring as shown and stake to the AVR bolt indicated. - Wrap nylon thread around the bolt as shown and tie around the bundle of battery wires. - The wires are now secure to the plate. 62 Rock. On! 2008

Step 3: Mounting Battery wires 63 Rock. On! 2008

Step 3: Mounting Battery wires 64 Rock. On! 2008

Step 3: Mounting Battery wires [plate overview] 65 Rock. On! 2008

Step 4: Mounting G-switch wires - Orient the G-switch wiring for mounting to the AVR bolt indicated. - Wrap nylon thread around the gold battery bracket as shown and tie around the bundle of G-switch wires. - Wrap nylon thread around the bolt as shown and tie around the bundle of G-switch wires. - The wires are now secure to the plate. 66 Rock. On! 2008

Step 4: Mounting G-switch wires 67 Rock. On! 2008

Step 4: Mounting G-switch wires 68 Rock. On! 2008

Step 5: Mounting Geiger wires - Orient the Geiger wiring for mounting to the Geiger bolt indicated. - Wrap nylon thread around the Geiger bolt as shown and tie around the bundle of Geiger wires. - The wires are now secure to the plate. 69 Rock. On! 2008

Step 5: Mounting Geiger wires [Geiger PCB overview] 70 Rock. On! 2008

Step 5: Mounting Geiger wires [Geiger PCB overview] 71 Rock. On! 2008

Step 5: Mounting Geiger wires [plate overview] 72 Rock. On! 2008

Indicator LED and RBF Wiring 73 Rock. On! 2008

Step 6: LED Mounting [General] - Make sure the Green LED is attached to the ‘ON’ header with the correct polarized orientation. - Additionally, make sure the connector for the Red LED is attached to the ‘RDY’ header in the correct orientation. - Extend all three sets of wires underneath the plate using the notch nearest the AVR as shown. 74 Rock. On! 2008

Step 6: LED Mounting [General] - Use copious amounts of hot glue without being overly excessive. - Keep the tip of the hot glue gun from touching hardware, only molten glue should touch the hardware. 75 Rock. On! 2008

Step 6: LED Mounting [General] - There are two orientations of LED mounting for the structures build. - If your plate serial number is odd (ending in 01, 03, 05) orient the LEDs in the first orientation given. This is opposite the Geiger Counter. - If your plate serial number is even (ending in 02, 04) orient the LEDs in the second orientation given. This is underneath the Geiger Counter. Example of an even plate serial number 76 Rock. On! 2008

Step 6: LED Mounting [General] - Extend the wiring underneath the plate and match the red ‘x’ mounting location as shown. - Mount the blue RBF wiring and stake near the middle of the appropriate notch on your plate. - Make sure the lip of the red LED connector is flush with the edge of the plate. - The front of the green LED should be even with the edge of the notch when mounting. - Consult the following pictures of each orientation with any questions. 77 Rock. On! 2008

LED Mounting: Odd Serial Number 78 Rock. On! 2008

Step 6: LED Mounting: Odd Serial Number - The red LED connector goes on top of the red x as shown. Orient the lip down and flush with the edge of the plate. - Also note the positive red wire is oriented inwards for this orientation. 79 Rock. On! 2008

Step 6: LED Mounting: Odd Serial Number - Have a partner hold the LED and RBF wiring in place. - Now hot glue the wiring in place in the same manner the photo shows. - Be careful not to burn your partner’s hand! 80 Rock. On! 2008

Step 6: LED Mounting [plate overview] Bottom View 81 Rock. On! 2008

LED Mounting: Even Serial Number 82 Rock. On! 2008

Step 6: LED Mounting: Even Serial Number - The red LED connector goes on top of the red x as shown. Orient the lip down and flush with the edge of the plate. - Also note the positive red wire is oriented outwards - Also notice the green LED is flush with the notch edge, but under the plate. 83 Rock. On! 2008

Step 6: LED Mounting: Second Orientation - Have a partner hold the LED and RBF wiring as shown. - Now hot glue the wiring in place in the same manner the photo shows. 84 Rock. On! 2008

Staking Components 85 Rock. On! 2008

Step 7: Staking bottom nuts -Add hot glue to the nuts on the bottom of the plate. -Stake all nuts on the bottom of the plate using hot glue as shown in the following two pictures. 86 Rock. On! 2008

Step 7: Staking bottom nuts Side View 87 Rock. On! 2008

Step 7: Staking bottom nuts 88 Rock. On! 2008

Step 8: Staking the AVR -Add hot glue across the AVR as shown for extra structural security. 89 Rock. On! 2008

Step 8: Staking the AVR Side View 90 Rock. On! 2008

Step 9: Staking connectors -Ensure all connectors are attached in the correct orientation. -Add generous amounts of hot glue to pot the connectors to the AVR PCB. -Now the wiring is mounted solidly to the AVR PCB. Example Connector 91 Rock. On! 2008

Step 9: Staking connectors Example Connector 92 Rock. On! 2008

Step 9: Staking connectors 93 Rock. On! 2008

Step 10: Staking Geiger Wires -Stake the soldering location of the Geiger wires on the Geiger PCB as shown. 94 Rock. On! 2008

Step 10: Staking Geiger Wires 95 Rock. On! 2008

Structures Overview: - Open your structures kit and verify its contents. - ESD protection should be utilized during the entire building process! - Make sure anyone handling the hardware is protected from ESD damage. - If any issues arise raise your hand for assistance. 96 Rock. On! 2008

Step 11: Staking AVR Wires -Stake the soldering location of the AVR wires on the AVR PCB as shown. 97 Rock. On! 2008

Step 12: Staking Accelerometer Nuts -Add hot glue to the Accelerometer nuts as shown. -You may also add hot glue to the wire leads of the Z-axis accelerometers if you desire. 98 Rock. On! 2008

Step 13: Staking Battery Bracket -Add hot glue to the areas shown on the battery bracket and connectors. 99 Rock. On! 2008

Step 13: Staking G-switch nuts -Add hot glue to the nuts on the G-switch as shown. 100 Rock. On! 2008

Step 14: Staking G-switch weights Before Staking 101 Rock. On! 2008

Step 14: Staking G-switch weights After Staking [back view] After Staking [front view] 102 Rock. On! 2008

Final Check 103 Rock. On! 2008

Bottom of an odd plate Staking should occur at all of these places!! 104 Rock. On! 2008

Top of an odd plate -Staking should occur at all of these places!!! -Set the completed Plate on the ESD mat and wait for further instructions. 105 Rock. On! 2008

Structural Integration 106 Rock. On! 2008

Structures Overview: - Open your structures kit and verify its contents. - ESD protection should be utilized during the entire building process! - Make sure anyone handling the hardware is protected from ESD damage. - If any issues arise raise your hand for assistance. 107 Rock. On! 2008

Overview: - Now that your payload has been built, tested, and mounted to a structural plate, it is time to assemble a stack of plates and integrate them into the Rock. Sat can configuration. 108 Rock. On! 2008

What Are We Building? 109 Rock. On! 2008

Structural Kit Overview: Parts from other kits G-switch (1) Blue RBF Wire (several feet) Red LED with connector (1) Green LED (1) 110 Rock. On! 2008

Step 6: LED Mounting: Odd Serial Number - The red LED connector goes on top of the red x as shown. Orient the lip down and flush with the edge of the plate. - Also note the positive red wire is oriented inwards for this orientation. 111 Rock. On! 2008

Final Product 1: Below: Stacked configuration in can. (Minus lid) Above: 5 plate stacked configuration. 112 Rock. On! 2008

Final Product 2: 5 Plate Stack Stand-offs attached to Top Lid. Barrel Section attached to Top Lid (8 Places) Assembled can with payload ~20 pounds Solid. Works model and actual picture of structural Rock. Sat can. 113 Rock. On! 2008

Groups and Hardware 114 Rock. On! 2008

Group Formation: To Begin: - Examine your plate for a serial number. The leading number indicates which can your team flies in, and the last two digits indicate plate number. Can Number Plate Number 115 Rock. On! 2008

Group Formation 2: - Find the other four (4) groups that have the same can number and sit together. (5 Plates total) - The assistants will come around and pass out the hardware that each team will need to build the Rock. Sat can structure. 116 Rock. On! 2008

Required Hardware 1: - One (1) Top Bulkhead - One (1) Bottom Bulkhead 117 Rock. On! 2008

Required Hardware 2: Wrenches Hex Key - One (1) 9/64 hex key - Two 5/16 open-end wrenches - Twenty (20) long malefemale (MF) stand-offs 118 Rock. On! 2008

Required Hardware 3: 3/8” - Five (5) malefemale (MF) short (cut-off) stand-offs - Five (5) female (FF) stand-offs 5/8” - Sixteen (16) 3/8” bolts - Five (5) 5/8” bolts 119 Rock. On! 2008

Required Hardware 4: 1/2” - Ten (10) locking washers - Five (5) 1/2’’ bolts 120 Rock. On! 2008

An Update 121 Rock. On! 2008

Update Note: - Some AVR boards were too close to a support stand-off during fit checks. 122 Rock. On! 2008

Update Note: - To help alleviate the issue, a small chunk was nipped from the edge of the board. - This should resolve the issue. - If at any time you are unsure if you may be doing damage to your board while installing stand-offs, please raise your hand. 123 Rock. On! 2008

Let’s Begin The Integration 124 Rock. On! 2008

Bottom Plate “ 01” Step 1: 3 2 2 1 4 5 - Take one (1) short stand-off and place the male end through one of the 5 holes on the plate with the serial number ending in “ 01. ” - The threaded end should protrude on the top side of the plate. 125 Rock. On! 2008

Bottom Plate “ 01” Step 2: - Screw on one (1) FF stand-off to the short MF stand-off you added. - Important: Tighten by hand until you cannot turn it anymore. 126 Rock. On! 2008

Bottom Plate “ 01” Step 3: - Use your wrenches to tighten the stand-off an extra quarter turn. (90° or π/2 radians) 127 Rock. On! 2008

Bottom Plate “ 01” Step 4: - Repeat the previous steps to add the other four (4) MF and FF stand-offs to plate “ 01” as shown. - Plate “ 01” should look similar to the pictures to the left. 128 Rock. On! 2008

Plate “ 02” Step 1: 3 2 1 4 5 - Take one (1) long stand-off and place the male end through one of the 5 holes on the plate with the serial number ending in “ 02. ” - The threaded end should protrude on the bottom side of the plate to thread into the FF stand-off on plate “ 01. ” 129 Rock. On! 2008

Clocking: AVR 05 AVR 04 AVR 03 AVR 02 AVR 01 - Clocking is a technique where each plate is rotated 180° relative to the previous plate. - Clocking is used here to better balance the Rock. Sat cans due to the CG not being exactly at the geometric center of the plate. 130 Rock. On! 2008

Plate “ 02” Step 2: Cloc ked 180° - Clock or rotate plate “ 02” 180° such that the AVR boards are opposite to each other. MF Stand-Off - Hand tighten the MF stand-off until you can turn it no further. 131 Rock. On! 2008

Plate “ 02” Step 3: - Use your wrenches to tighten the stand-off an extra quarter turn. (90° or π/2 radians) 132 Rock. On! 2008

Plate “ 02” Step 4: 4 3 1 5 2 - Repeat the previous steps to mate the MF stand-offs into the FF stand-offs on the deck below. - Plates “ 01” and “ 02” should look similar to the pictures to the left. 133 Rock. On! 2008

Plate “ 03” Step 1: 3 2 1 4 5 - Take one (1) long stand-off and place the male end through one of the 5 holes on the plate with the serial number ending in “ 03. ” - The threaded end should protrude on the bottom side of the plate to thread into MF stand-off on plate “ 02. ” 134 Rock. On! 2008

Clocked 180 MF Stand-Off ° Plate “ 03” Step 2: - Clock or rotate plate “ 03” 180° such that the AVR boards on plate “ 02” and “ 03” are opposite to each other. - Hand tighten the MF stand-off until you can turn it no further. 135 Rock. On! 2008

Plate “ 03” Step 3: - Use your wrenches to tighten the stand-off an extra quarter turn. (90° or π/2 radians) 136 Rock. On! 2008

Plate “ 03” Step 4: 2 3 1 5 - Repeat the previous steps to mate the MF stand-offs into the MF stand-offs on the deck below. 4 - Your stack should resemble the picture to the left. 137 Rock. On! 2008

Plate “ 04” Step 1: 3 2 1 4 5 - Take one (1) long stand-off and place the male end through one of the 5 holes on the plate with the serial number ending in “ 04. ” - The threaded end should protrude on the bottom side of the plate to thread into MF stand-off on plate “ 03. ” 138 Rock. On! 2008

Plate “ 04” Step 2: ed k oc Cl MF Stand-Off 0 18 ° - Clock or rotate plate “ 04” 180° such that the AVR boards on plate “ 04” and “ 03” are opposite to each other. - Hand tighten the MF stand-off until you can turn it no further. 139 Rock. On! 2008

Plate “ 04” Step 3: - Use your wrenches to tighten the stand-off an extra quarter turn. (90° or π/2 radians) 140 Rock. On! 2008

Plate “ 04” Step 4: 3 2 1 5 4 - Repeat the previous steps to mate the MF stand-offs into the MF stand-offs on the deck below. - Your stack should resemble the picture to the left. 141 Rock. On! 2008

Plate “ 05” Step 1: 3 2 1 4 5 - Take one (1) long stand-off and place the male end through one of the 5 holes on the plate with the serial number ending in “ 05. ” - The threaded end should protrude on the bottom side of the plate to thread into MF stand-off on plate “ 04. ” 142 Rock. On! 2008

Cl oc ke d 18 0° Plate “ 05” Step 2: MF Stand-Off - Clock or rotate plate “ 05” 180° such that the AVR boards on plate “ 05” and “ 04” are opposite to each other. - Hand tighten the MF stand-off until you can turn it no further. 143 Rock. On! 2008

Plate “ 05” Step 3: - Use your wrenches to tighten the stand-off an extra quarter turn. (90° or π/2 radians) 144 Rock. On! 2008

Plate “ 05” Step 4: 4 5 1 3 2 - Repeat the previous steps to mate the MF stand-offs into the MF stand-offs on the deck below. - Your stack should resemble the picture to the left. 145 Rock. On! 2008

Bottom Bulkhead 1: - Carefully turn the stack upside down. - Place the bottom bulkhead (with the outer bolt circle) on the bottom of the stack - Make sure the notch aligns with the set of blue RBF wires as shown. 146 Rock. On! 2008

Bottom Bulkhead 2: - Take one (1) 1/2” bolt and locking washer and hand screw it into the center stand-off as shown. 147 Rock. On! 2008

Bottom Bulkhead 2: - Lightly tighten the 1/2” bolt and lock washer with the hex key. - Important: Don’t not over tighten the bolt. After all bolts are in, they will be torqued to 30 in*lbs. 148 Rock. On! 2008

Bottom Bulkhead 3: 4 3 1 5 2 - Insert and tighten the remaining four (4) 1/2” bolts and washers on the bottom bulkhead. - Note: Add the bolts in an alternating fashion (like tire lug nuts) as indicated above. Tighten until bolts are flush with the plate. 149 Rock. On! 2008

Bottom Bulk Head 4: - Have two people in the group carefully rotate the stack 180° so that it now rests on the bottom bulkhead. - Your stack should resemble the picture to the left. 150 Rock. On! 2008

Outer Skin 1: - Ensure that the blue wires all pass down the channel with the LEDs. - Also check that no wires or objects are on the edge of any of the plate. - Place the outer skin onto the bottom bulkhead. 151 Rock. On! 2008

Outer Skin 2: - Align the outer skin to allow the skin and bulkhead holes to line up. - By hand, screw in all eight (8) 3/8” bolts through the skin to attach it to the bottom bulkhead. - Important: Do not over tighten the bolts. The bolts will be torqued to 30 in*lbs 8 Total Good Alignment 152 Rock. On! 2008

Outer Skin 3: - Use the hex key to lightly tighten all eight (8) 3/8 bolts - Note: Use an alternating pattern (like tire lug nuts). - Caution: Do not over tighten the bolts. The bolts will be torqued to 30 in*lbs once all structural bolts are installed. 153 Rock. On! 2008

Outer Skin 4: - Your structure should now resemble the picture to the left. 154 Rock. On! 2008

Outer Skin 5: - Place the top bulkhead on the stack as shown to the left. - Make sure that the notch aligns with the wire path way. 155 Rock. On! 2008

Outer Skin 6: - Align the outer skin to allow the skin and bulkhead holes to align. - By hand, screw in all eight (8) 3/8” bolts into the skin to attach it to the top bulkhead. 8 Total Good Alignment 156 Rock. On! 2008

Outer Skin 7: - Use the hex key to lightly tighten all eight (8) 3/8 bolts - Note: Use an alternating pattern (like tire lug nuts). - Caution: Do not over tighten the bolts. The bolts will be torqued to 30 in*lbs once all structural bolts are installed. 157 Rock. On! 2008

Outer Skin 8: - Your structure should now resemble the picture to the left. 158 Rock. On! 2008

Top Bulk Head 1: - You might find that your top bulkhead bolts don’t align perfectly. - If this is the case, reach in through a window and apply a small amount of force to achieve alignment. 159 Rock. On! 2008

Top Bulkhead 2: - Once alignment is achieved, insert one (1) 5/8” bolt and lock washer into the center hole. - Lightly tighten the bolt with the hex key. - Important: Leave this bolt loose enough to make slight adjustments to the other four (4) bolts. 160 Rock. On! 2008

Top Bulkhead 3: - By hand, lightly screw in the other four (4) 5/8” bolts and lock washers. 161 Rock. On! 2008

Top Bulkhead 4: - Use your hex key to tighten all five (5) 5/8” bolts and lock washers on the top of the bulkhead. 162 Rock. On! 2008

Top Bulkhead 5: - Your structure should look like this, but with more wires coming down the pass -through. - Note: All LEDs and connectors should be visible in the wire way. 163 Rock. On! 2008

Final Product: Congratulations! You have completed integration of your payload with the Rock. Sat can. We will now walk through a shorting plug test, pull the RDY LED, and get all structural bolts torqued and ready for the hand-off to Wallops engineers! 164 Rock. On! 2008