1. RockOn! 2008 1 RockOn! Structure Build RockOn! 2008

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

7. RockOn! 2008 7 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.

8. RockOn! 2008 8 Structural Kit Overview: Nuts and Bolts Purple M3.0x10 (2) M2.0 nuts (2) Light Green M2.5x10 (3) M2.5 nuts( 3) Black M3.0x25 (4) Red M3.0x35 (4) Light Blue M3.0x10 (4) Red M2.0x10 (2) M3.0 nuts (16) Light Green M3.0x10 (2) *Bolts and nut are 1:1 scale Nylon spacers (24)

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

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

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

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

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

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

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

16. RockOn! 2008 16 Let’s Start Building! RockOn! 2008

17. 17 Structural Kit: Completed Plate

18. RockOn! 2008 18 Step 1: AVR Mounting -Find the M3.0x25 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 M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

19. RockOn! 2008 19 Step 1: AVR Mounting x4 for all holes on the AVR ***Note the orientation of the AVR***

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

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

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

23. RockOn! 2008 23 Step 2: Z Accelerometer Mounting -Find the M3.0x10 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 M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

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

25. RockOn! 2008 25 Step 2: Z Accelerometer Mounting

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

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

28. RockOn! 2008 28 Step 3: Z Accelerometer Mounting -Find the M2.5x10 Light Green bolts for the Z accelerometer. -Mount the Z accelerometer as shown. -Hand tighten with an M2.5 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 M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

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

30. RockOn! 2008 30 Step 3: Z Accelerometer Mounting

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

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

33. RockOn! 2008 33 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 “-”.

34. RockOn! 2008 34 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.

35. RockOn! 2008 35 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.

36. RockOn! 2008 36 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 M3.0x35 bolts mount the Geiger Board to the plate as shown. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

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

38. RockOn! 2008 38 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.

39. RockOn! 2008 39 Step 6: G Switch Bracket Mounting -Find the G Switch bracket and mount to the plate as shown. -The mounting bolts are two M3.0x10 colored purple. -The holes to be mounted are closest the bend in the ‘L’ bracket. -Finger tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

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

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

42. RockOn! 2008 42 Step 7: G Switch Mounting -Find the G Switch and mount to the G Switch bracket. -The mounting bolts are two M2.0x10 colored red. -Finger tighten the bolts with M2.0 nuts plus an additional ½ turn using the pliers and screwdriver.

43. RockOn! 2008 43 Step 7: G Switch Mounting

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

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

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

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

48. RockOn! 2008 48 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 3.0x10 bolts colored light blue. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench. -Mount the ‘L’ bracket first pushing the batteries flush with it on the plate.

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

50. RockOn! 2008 50 Step 8: Battery Bracket Mounting

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

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

53. RockOn! 2008 53 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.

54. RockOn! 2008 54 Staking and Mounting RockOn! 2008

55. 55 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. RockOn! 2008 56 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.

57. RockOn! 2008 57 Step 1: Mounting the AVR

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

59. RockOn! 2008 59 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!!!

60. RockOn! 2008 60 Step 2: Bundling Wires AVR Overview

61. RockOn! 2008 61 Step 2: Bundling Wires Plate Overview

62. RockOn! 2008 62 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.

63. RockOn! 2008 63 Step 3: Mounting Battery wires

64. RockOn! 2008 64 Step 3: Mounting Battery wires

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

66. RockOn! 2008 66 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.

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

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

69. RockOn! 2008 69 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.

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

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

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

73. RockOn! 2008 73 Indicator LED and RBF Wiring RockOn! 2008

74. 74 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.

75. RockOn! 2008 75 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.

76. RockOn! 2008 76 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

77. RockOn! 2008 77 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.

78. RockOn! 2008 78 LED Mounting: Odd Serial Number RockOn! 2008

79. 79 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.

80. RockOn! 2008 80 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!

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

82. RockOn! 2008 82 LED Mounting: Even Serial Number RockOn! 2008

83. 83 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.

84. RockOn! 2008 84 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.

85. RockOn! 2008 85 Staking Components RockOn! 2008

86. 86 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.

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

88. RockOn! 2008 88 Step 7: Staking bottom nuts

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

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

91. RockOn! 2008 91 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

92. RockOn! 2008 92 Step 9: Staking connectors Example Connector

93. RockOn! 2008 93 Step 9: Staking connectors

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

95. RockOn! 2008 95 Step 10: Staking Geiger Wires

96. RockOn! 2008 96 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.

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

98. RockOn! 2008 98 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.

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

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

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

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

103. RockOn! 2008 103 Final Check RockOn! 2008

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

105. RockOn! 2008 105 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.

106. RockOn! 2008 106 Structural Integration RockOn! 2008

107. 107 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.

108. RockOn! 2008 108 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 RockSat can configuration.

109. RockOn! 2008 109 What Are We Building? RockOn! 2008

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

111. RockOn! 2008 111 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.

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

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

114. RockOn! 2008 114 Groups and Hardware RockOn! 2008

115. 115 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

116. RockOn! 2008 116 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 RockSat can structure.

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

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

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

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

121. RockOn! 2008 121 An Update RockOn! 2008

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

123. RockOn! 2008 123 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.

124. RockOn! 2008 124 Let’s Begin The Integration RockOn! 2008

125. 125 Bottom Plate “01” Step 1: -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. 5 2 1 3 4 2

126. RockOn! 2008 126 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.

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

128. RockOn! 2008 128 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.

129. RockOn! 2008 129 Plate “02” Step 1: -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.” 5 2 1 3 4

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

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

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

133. RockOn! 2008 133 Plate “02” Step 4: -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. 1 2 3 4 5

134. RockOn! 2008 134 Plate “03” Step 1: -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.” 5 2 1 3 4

135. RockOn! 2008 135 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. Clocked 180° MF Stand-Off

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

137. RockOn! 2008 137 Plate “03” Step 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. 1 2 3 4 5

138. RockOn! 2008 138 Plate “04” Step 1: -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.” 5 2 1 3 4

139. RockOn! 2008 139 Plate “04” Step 2: -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. Clocked 180° MF Stand-Off

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

141. RockOn! 2008 141 Plate “04” Step 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. 1 2 3 4 5

142. RockOn! 2008 142 Plate “05” Step 1: -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.” 5 2 1 3 4

143. RockOn! 2008 143 Plate “05” Step 2: -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. Clocked 180° MF Stand-Off

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

145. RockOn! 2008 145 Plate “05” Step 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. 1 2 3 4 5

146. RockOn! 2008 146 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.

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

148. RockOn! 2008 148 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.

149. RockOn! 2008 149 Bottom Bulkhead 3: -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. 1 3 4 2 5

150. RockOn! 2008 150 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.

151. RockOn! 2008 151 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.

152. RockOn! 2008 152 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. Good Alignment -Important: Do not over tighten the bolts. The bolts will be torqued to 30 in*lbs 8 Total

153. RockOn! 2008 153 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.

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

155. RockOn! 2008 155 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.

156. RockOn! 2008 156 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. Good Alignment 8 Total

157. RockOn! 2008 157 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.

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

159. RockOn! 2008 159 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.

160. RockOn! 2008 160 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.

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

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

163. RockOn! 2008 163 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.

164. RockOn! 2008 164 Final Product: Congratulations! You have completed integration of your payload with the RockSat 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!