Ron Gross Scratchbuilding the Jupiter 2
Scratchbuilding the Jupiter 2 by Ron Gross
After completing his research and blueprints for the model, Ron had hull patterns created by a contractor using a CAD assisted process. The results were satisfactory and the pattern only required minimal adjustment. This photo demonstrates the final refinement of the master upper hull pattern.
Once Ron was confident that the master patterns were a perfect translation of his blueprints, he created molds using RTV silicone rubber. This photo shows the patterns with the finished molds.
Ron found fiberglass to work better than resin for this hollow cast model. Initial impression coatings of thixotropic resin were applied to the mold, followed by fiberglass cloth, saturated with laminating resin. This was tightly worked into each cavity and allowed to cure.
Once the castings were extracted from the molds, the edges were finished using a small hobby saw, and multiple sheets of sandpaper attached to a flat platform.
Here you see the completed hull sections with openings cut for the ports and windows.
This side view of the completed top hull piece shows the opening cut for the main window. Note the sharply defined contour of the hull. This is one of the main aspects of the ship that Ron was striving to accurately recreate.
Ron went to great lengths to create an accurate fusion core. A pattern was carefully created and RTV molds were produced. A surface covering layer of clear epoxy resin was applied and allowed to cure, then the mold was filled with more two part clear epoxy.
Here you see parts of the mold for the reactor core. On the left is the original pattern. Top is the mold, and right is the plug for inside of the mold. On the bottom you see the finished core piece.
For the landing gear, patterns were created and parts were cast in resin. Here you see the pattern on top, the RTV molds, and castings of the landing pads and legs.
The top dome was created by pushing a pattern into a piece of heated clear acetate. The part was then carefully trimmed.
This is the lighting circuit that sits in the reactor core. It features 32 LEDs in a circular configuration. They illuminate in a clockwise fashion, and the rotation can be controlled by a variable speed resistor. This circuit also controlled the lights in the dome. Check out Ron’s custom lighting circuit details.
The flight deck console was built from plastic sheet and features detailed control panels. These panels are printed on clear acetate for lighting.
Here is a close up of the console in place, and backlit.
Internal lighting was accomplished using a single curved piece of Light Sheet. You can see the electronics, lightsheet driver, and power supply in this shot. Also note the lights for the top dome.
