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Giant Leap Rocketry TALON 6 Instructions Manual Download Page 13

the centering rings and apply epoxy sparingly between both centering rings on each 
mounting collar.  Re-tighten the u-bolts, clean up excess epoxy and be certain the rings 
are centered one to the other and will slip over the 3.9”x 8” phenolic tube.  

BE 

CERTAIN NO EPOXY MIGRATES INTO THE THREADED INSERTS OR THE 
KEVLAR BRIDLE.

  Take that collar assembly and epoxy to one end of the 3.9”x 8” 

phenolic tube 

U-BOLTS FACING AWAY FROM THE TUBE 

so the end of the tube 

is 

FLUSH

 with the centering ring containing the threaded inserts.  Only epoxy one of 

the collar assemblies on at this time, set aside and allow curing. 

 

 

  

 

 

 
Find the av-bay kit and the two rounded corner plywood endplates.  First, open the av-
bay kit and remove the two larger body bulkheads and set aside.  You will 

NOT 

use 

them.  Instead the rounded corner endplates will be substituted.  Assemble that kit per 
the included instructions so the rounded corner endplates are oriented the same direction 
on either end of the av-bay.

  

 

 

  

 

 

 

 

Temporarily remove one of the rounded corner endplates (wing nut side) and insert into 

Summary of Contents for TALON 6

Page 1: ...TALON 6 INSTRUCTIONS Revision A GIANT LEAP ROCKETRY INC KB KITS LLC www giantleaprocketry com http www giantleaprocketry com 6061 HIBISCUS DR BATON ROUGE LA 70808 Ph 225 9564 0325 ...

Page 2: ...the center of pressure with 1 5 diameters being ideal All measurements need to be done with a full up rocket including motor recovery components and any electronics SPECIFICATIONS Length 124 Diameter 6 0 Dry weight 25lbs fiberglass Full up weight with motor chute electronics Approx 42 5lbs Motor mount 75mm Recommended parachute sizes Drogue parachute Giant Leap Rocketry TAC 9 Drogue or TAC 1 36 Ma...

Page 3: ...ND OF THESE INSTRUCTIONS IF YOU HAVE ANY QUESTIONS OR ARE UNCLEAR REGARDING THE ASSEMBLY OF USE OF THIS PRODUCT PLEASE CALL GIANT LEAP ROCKETRY INC You are totally responsible for the safe usage of this rocket Follow all pertinent safety codes and directions at the launch site Always wear eye protection whenever loading ejection charges of any type and keep spectators away Make a checklist to help...

Page 4: ... 3 9 Giant Leap Rocketry Phenolic Av Bay 2 5 5 x 3 75 x 1 4 plywood board with rounded ends for electronics bay caps with one 1 4 hole and two 5 15 holes 4 5 16 quick links 4 1 4 x 20 stainless steel pan head machine screws 2 av bay collar assemblies each with one 6 0 x 3 9 center ring one 6 0 x 3 9 coupler centering ring two u bolts two threaded inserts and attached Kevlar bridle 1 3 9 x 8 phenol...

Page 5: ...H3660 hardener recommended Small wood sticks or tongue depressors Expanding Mega Foam quarter sheet electric sander Assortment of sandpaper 60 120 180 220 320 and 400 grit Xacto type razor saw BEFORE YOU BEGIN confirm that all the parts are included in this kit Also be certain you have all the supplies needed by the builder to complete the Talon 6 AND FINALLY YOU MUST READ AND UNDERSTAND THE INSTR...

Page 6: ... coupler centering ring assembly with two pre mounted u bolts IT IS VERY VERY IMPORTANT THAT YOU ARE NEAT AND DO NOT ALLOW ANY EPOXY RUNS OR SLOPPINESS ANYWHERE DURING THIS OR ANY OTHER PHASE OF CONSTRUCTION Begin by mounting the 75mm Slimline motor retainer on one end of the 3 0 x 48 phenolic tube as per the enclosed instructions in the Slimline kit Please use JB Weld for attachment and allow cur...

Page 7: ...THIS ASSEMBLY IS SQUARE TO THE MOTOR TUBE AND USE TAPE TO HOLD IN POSTION THIS IS A CRITICAL JOINT AND MUST BE STRONG BE CERTAIN THIS ASSEMBLY IS 21 TO THE VERY CLOSEST PART OF THE PREVIOUSLY MOUNTED SLIMLINE Be sure you place epoxy on all mating surfaces and have fillets on both sides of the centering rings ALLOW THIS JOINT TO CURE WITH NO EPOXY RUNS Also place a small drop of epoxy on the expose...

Page 8: ...12 x 3 0 phenolic tube and 6 x 3 0 split outside coupler You are now going to take the previous 48 motor tube and extend it 12 by sliding the split coupler over the OUTSIDE of the 3 0 x 12 extension Now butt the extension to the 48 x 3 motor tube end opposite of the Slimline retainer Slide the split coupler over the joint of the two tubes until the coupler is equal in length on both sides of the j...

Page 9: ...g a piece of fiberglass or carbon fiber cloth between the two Whatever you choose you need to apply either epoxy adhesive or epoxy laminating resin to bond the two couplers together You will insert the smaller coupler inside the outer cut the tape and allow it to expand After you have joined the two couplers together BUT BEFORE THE EPOXY CURES SLIDE THE INSIDE COUPLER SO THERE EQUAL SPACE BETWEEN ...

Page 10: ...the c ring assembly AND THE LOOPS OF THE U BOLTS ARE PROTRUDING OUTSIDE OF THE COUPLER If satisfied remove the c ring assembly and loosen not remove the u bolts so you can spread a thin layer of epoxy between the c rings tighten the u bolts and confirm that the assembly will still slide inside of the coupler If not loosen the u bolts and adjust the c rings until the assembly will fit inside the ...

Page 11: ...g of the Kevlar cord to be mounted in the next step Set aside to cure completely With the Kevlar cord find and mark the center point Take the finished c ring assembly and with one end of the Kevlar cord LOOP AROUND AND THROUGH ONE U BOLT and continue by inserting through the 1 2 opening adjacent to that u bolt Pull several feet of the cord through that opening Now take the other end of the Kevlar ...

Page 12: ...g collar assemblies each includes one each body and coupler centering ring with two attached u bolts two threaded inserts and one Kevlar bridle One 3 9 x 8 phenolic tube Two 5 5 x 3 75 rounded corner plywood endplates One Giant Leap Rocketry 3 9 Av Bay Four 1 4 x 20 stainless steel pan head machine screws One 1 2 x 25 Kevlar Shock loop and piston assembly Two 5 16 quick links Locate the two av bay...

Page 13: ... TUBE so the end of the tube is FLUSH with the centering ring containing the threaded inserts Only epoxy one of the collar assemblies on at this time set aside and allow curing Find the av bay kit and the two rounded corner plywood endplates First open the av bay kit and remove the two larger body bulkheads and set aside You will NOT use them Instead the rounded corner endplates will be substitute...

Page 14: ... install the two machine screws finger tight DO NOT USE ANY EPOXY YET Slide the second collar assembly onto the opposite end of the 3 9 x 8 tube with the u bolts again facing outward followed by the rounded corner endplate over the av bay all threads Re attach the av bay wing nuts onto the all threads and rotate the loose av bay collar so you can attach and finger tighten the two machine screws th...

Page 15: ... x 8 tube will still slide into the rings BE CERTAIN NO EPOXY MIGRATES INTO THE THREADED INSERTS OR THE KEVLAR BRIDLE Attach this collar onto the tube in the same manner as done previously BEING CERTAIN THE PREVIOUSLY MADE WITNESS MARKS LINE UP AND NO EPOXY MIGRATES TO THE THREADED INSERTS KEVLAR BRIDLES OR INSIDE OF THE 3 9 X 8 TUBE Set aside to cure When done go back and make certain all the u b...

Page 16: ...holder inside the airframe it doesn t matter which way until it is in position INSIDE OF BOTH MARKS drawn previously IMMEDIATELY WIPE UP EXCESS EPOXY BEING CERTAIN NONE GETS ON THE KEVLAR BRIDLES OR THREADED INSERTS Let the airframe lay on its side occasionally rolling to prevent the epoxy from pooling REMOVE ALL EXCESS EPOXY Allow to cure Standing the airframe on one end apply a small epoxy fille...

Page 17: ...e air pressure to fluctuate in the electronics section for altimeter readings into the electronics area The opening should be 1 4 in diameter THROUGH THE AIRFRAME ONLY AT THIS TIME Place wide masking tape on all sides around this opening and have a large number of paper towels available for the next step Mix a small amount of two part foam no more than one ounce total per each attempt and pour int...

Page 18: ...and piston parts First take the Kevlar shock loop and thread through the hole drilled in the bulkhead Pull eight to ten feet of cord through and tie a knot AS CLOSE AS POSSIBLE ON BOTH SIDES of the bulkhead hole that will prevent the piston from moving one way or another on the Kevlar cord DO NOT FILL OR EPOXY THE OPENING TO DO SO WILL MAKE THE KEVLAR BRITTLE AND AT RISK OF BREAKING UNDER STRESS T...

Page 19: ...e to the Kevlar bridle found at the av bay holder 14 15 inside of the upper airframe Because of customer requests for the Talon 6 to be dual deployment yet keeping the size of the rocket the same an unusual technique must be employed to provide adequate space for the main parachute It will be necessary for at least some of the parachute to be packed inside of the nosecone it is recommended that a ...

Page 20: ... CHUTE PROPERLY DEPLOYS AND ANY SHEAR PINS UTILIZED BREAK CLEANLY AND EVENLY JOINING OF SUB ASSEMBLIES Please locate the following items Tail cone Motor tube assembly Slotted airframe Double walled coupler or fiberglass coupler for the fiberglass kit with centering ring assembly including u bolts and Kevlar cord Two 5 16 quick links One 1 2 x 25 Tubular Kevlar Shock loop First TEST FIT WITHOUT ADH...

Page 21: ...do this step prior to MOUNTING OF COUPLER TO AIRFRAME instructions For now please continue with the instructions detailing how to join the motor mount tube to the tail cone FIBERGLASS you are going to attach the Kevlar cords from the bulkhead Kevlar cord assembly to the motor mount tube First stretch out the cords in straight parallel lines and remove all kinks so they are smooth Insert one cord e...

Page 22: ...er the mating contact edges of the above mentioned centering rings with epoxy Once this is done stand the tail cone vertically small end down and insert the motor tube assembly STRAIGHT DOWN until the motor tube Slimline is flush with the small end of the tailcone opening IMMEDIATELY CHECK THE SLIMLINE TO CONFIRM THERE IS NO EPOXY OR JB WELD ON ANY INTERIOR SURFACE REMOVE ANY IF PRESENT FAILURE TO...

Page 23: ... utilizes a double wall coupler some assembly procedures are different from the fiberglass version The next two paragraphs are for the phenolic version THE FOLLOWING PROCEEDURES ARE NOT DIFFICULT BUT THEY ARE INVOLVED BE PATIENT AND READ EVERYTHING FIRST BEFORE ATTEMPTING THE FOLLOWING Locate the phenolic double wall coupler centering ring assembly with u bolts and Kevlar cord assembled motor moun...

Page 24: ... bolts THESE KNOTS ARE CRITICAL IF THEY FAIL YOU WILL LOSE YOUR ROCKET Separate the coupler centering ring assembly from the coupler as far as the Kevlar cords will allow TEMPORARILY TEST FIT by completely sliding the motor tube tailcone assembly into position inside of the airframe Rotate the tailcone motor tube so NO KEVLAR CORDS ARE UNDERNEATH THE FIN SLOTS OF THE AIRFRAME AND THE WITNESS MARKS...

Page 25: ...R THE FIN SLOTS OR THE EXTERIOR OF THE COUPLER If you wish you may temporarily tape these items together to retain position and allow the epoxy to cure Set aside and allow curing When curing is complete TEMPORAILY TEST FIT by first inserting the coupler centering ring assembly with Kevlar cord attached to the motor tube tailcone assembly into the airframe to check the fit of the forward centering ...

Page 26: ...DO NOT PUT TOGETHER YET Quickly apply a ring of epoxy inside the coupler below the mark drawn previously where the lower coupler centering ring resides THE EPOXY WILL GO BELOW THE MARK MAKING A RING ONE INCH WIDE QUICKLY slide the motor tube tailcone into the airframe MATCHING THE TWO WITNESS MARKS TOGETHER Clean up all excess epoxy around the tailcone airframe joint all fin slots and around the c...

Page 27: ...ximately one inch wide around the top edge of the coupler and a light coat on the outside edges of the centering ring assembly Permanently press into position the centering ring assembly inside of the coupler with approximately1 8 of coupler extending above the bulkhead assembly WARNING BE CERTAIN ALL EXCESS KEVLAR CORD IS PULLED OUT OF THE AIRFRAME COUPLER AND THE HOLES IN THE CENTERING RING ASSE...

Page 28: ... A PHENOLIC AIRFRAME NOW IS AN EXCELLENT TIME TO COVER THE TUBING WITH EITHER FIBERGLASS CARBON FIBER OR THE ENCLOSED EZ GLASS SOCK REEINFORCEMENT It is unnecessary to cover a fiberglass airframe with tube reinforcement BUT IT IS IMPORTANT WHICHEVER TALON 6 YOU PURCHASED THAT YOU APPLY A 2 WIDE STRIP OF FIBERGLASS TAPE AND RESIN COMPLETELY AROUND THE TAILCONE BODY TUBE JOINT Failure to do so will ...

Page 29: ... later remove the tape prior to complete curing of the epoxy and remove any excess epoxy This will need to be trial and error timing on the builder s part as all cure rates are different But be certain that the two parts stay locked together and in line with one another When completed remove the tape and inspect your results Check to see that both parts are firmly locked together and straight in l...

Page 30: ...y epoxy in a similar method to your practice exercise above wipe off excess epoxy tape and allow curing To speed up the process you can apply edging in the same method to the opposite edge DO NOT APPLY EDGING TO THE FIN TIP UNTIL NOTIFIED Do this procedure to all the leading and trailing edges for the upper and lower fins Set aside and allow curing flat on the wax paper surface When finished remov...

Page 31: ...ips of all fins MAKING SURE THAT EXCESS EDGING EXTENDS PAST THE PREVIOUSLY MOUNTED LEADING AND TRAILING EDGING When completed trim and sand the excess edging in the same line as the previous edging Now you can flat sand the faces of all the fins and edges BEING CERTAIN NOT TO SAND INTO THE COMPOSITE FIN MATERIALS It will be necessary to fill the cavities left on the tip edging prior to shaping of ...

Page 32: ...g tape to keep the fin perpendicular to the airframe Now repeat the above procedure with a smaller fin into the slot below the just attached larger fin Again clean excess epoxy away and use masking tape to hold the fin in place MAKING SURE BOTH UPPER AND LOWER FINS ARE IN LINE WITH ONE ANOTHER Allow assembly to cure Only after the epoxy has cured for these fins can you turn the airframe and attach...

Page 33: ...e Talon6 utilizes rail buttons in three locations These rail buttons may look small but they are quite sufficient for the task and fit a standard 1 x 1 launch rail First locate the upper airframe section and drill a 3 32 hole 26 UP FROM THE END WHERE THE BOOSTER SECTION COUPLER SLIDES INTO DRILLING INTO THE UPPER COLLAR OF THE PREVIOUSLY ATTACHED AV BAY HOLDER AND NO MORE THAN DEEP Utilizing the i...

Page 34: ... and a 2 3 oz black powder charge is utilized for each ejection container in the main parachute section BE ABSOLUTELY CERTAIN THE CHARGES ARE PACKED AND SEPARATED TO PREVENT ONE CHARGE FROM BLOWING THE SECOND CHARGE SIMULTAINOUSLY Pack cellulose insulation around and between both charge units FINALLY YOU MUST GROUND TEST BOTH DROGUE AND MAIN PARACHUTE DEPLOYMENT CHARGES WITH PARACHUTES MOUNTED TO ...

Page 35: ...lied including but not limited to non infringement of third party rights merchantability or fitness for a particular purpose with respect to the product and any related published materials To the extent you use or implement our products or information in your own setting you do so at your own risk In no event will Giant Leap Rocketry Inc be liable to you for any damages arising from your use or yo...

Page 36: ...Launch a high power rocket only in an outdoor area where tall trees power lines and buildings will not present a hazard to the safe flight operation of a high power rocket in the opinion of the Safety Monitor 13 2 Do not locate a launcher closer to the edge of the flying field launch site than one half the radius of the minimum launch site dimension stated in Table 1 13 3 The flying field launch s...

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