Card in Space 2

Project Mercury - Redstone Launch Vehicle

Mission MR-3 / Freedom 7 / Alan B. Shepard
Cardmodel in 1:48 scale - 173 parts
Designed by Michael Urban

Thanks to David Weeks for providing information & NASA for images.

Copyright 2004 by Michael Urban. All Rights Reserved. Unauthorized reproduction or distribution prohibited.
Duplication allowed for personal use only.
1 Propulsion Section Body

Roll part 1 into a cylinder and glue together using connector strip 1a.
4
Glue part 2 to the inside of the upper border of part 1. Make sure that
3 the small gap in the upper border is not obstructed.

Glue part 3 to the inside of part 2 so that the small stripe in the middle
is visible above the top of part 1. Make sure that the cutout matches the
cutout in part 1 and 2.
2
Glue part 4 around the outside of the upper area of part 3.

Depending on the thickness of the paper you used to print the parts,
you might have to slightly adjust the lengths of part 2 to 4.

1a

2 Body Formers & Hydrogen Peroxide Fill and Drain

Fold part 6 and glue the flaps together so that a recessed area is
formed.
6
Roll part 7 into a cylinder and glue to the marking on part 6.
8 7
Glue part 8 on top of part 7.

Laminate former 1b to double thickness and glue to the inside of part 1,

sitting flush with the bottom of part 2.
1b
Laminate part 5 to double thickness and glue flush to the bottom of part
1.
Position the assembly 6-8 at the cutout of part 1 and glue it from the
inside. The small cylinder must be positioned in the lower half of the
assembly.
5

3 Fin Assembly

Fold part 9 in the middle and glue the backsides of the part together.
10 Glue the stringers 10 and 11 to the markings on both sides of part 9.
13
Fold and glue part 12 to the underside and front of part 9.
14
Repeat the above steps 4 times.
11 15
Fold the fin skins part 13-16 and the folding marks. Slightly round the
16 ends of the parts so that they form a smooth fairing towards the body of
9 the propulsion section. The rounding should begin aft of part 10.

12
4 Fin Mounting, Aerodynamic Rudders, Pneumatic Connectors

Mount the fin assemblies to the propulsion section. Pay attention to

which fin goes where - the white/black color on the fins and on the body
tube must match. Glue the rounded fairings to the tube so that it
21 21 matches the triangular outline marked on the tube.

Fold and glue 4 aerodynamic rudders from parts 17.

Glue four parts 18 to the tips of the fins and glue the aerodynamic
rudders to these parts.
19
20 Build the two pneumatic connectors from parts 19, 20 and 21 and glue
them to the corresponding markings on the tube.

18
17

5 Thrust Ring and Vane Guides

25 Build the thrust ring from formers 22, inner ring 23 and outer ring 24.
22 Glue to the marking on the bottom plate.
23
24 Fold four vane guides from parts 25 and glue onto the markings.

6 Flame Shields and Carbon Vanes

27 28 29 30
26 Build four flame shields from part 26 and 27. Glue both parts together
as shown in the image. Then, glue them to the bottom of the fins and
31 the body tube.

Build four carbon vanes from parts 28 to 31. Glue to the flame shields
as shown in the image.
7 Fill and Drains, Vents
32
Cut out the main body skin 32 and cut out the three circles marked with
a red C that are located near the bottom end of the skin. Be careful
with the rightmost circle as it is near the border of the part. You might
want to glue the connector strip 32a to the right edge of the part first to
give you more material there. The connector strip must also be partially
cut out.

Assemble the LOX Fill and Drain by glueing part 36 to the back of 35
and then part 37 to the center mark of 36. Round the part a bit so that it
conforms to the roundness of the rocket skin and glue it to the back of
part 32, behind the leftmost hole.

Repeat the process with the Fuel Fill and Drain, using parts 38-40 and
glue it behind the middle hole.
35 37 36 41 42 43
Finally, assemble the LOX Vent using parts 41-43 and glue it behind
38 40 39 the rightmost hole.

8 Instrumentation Unit

Roll the Instrumentation Unit Skin 35 into a tube and close with
35a 35 connector strip 35a.

Glue spacer 33 to the inside of the tube, flush with the bottom.

Glue the Stage Connector 34 to the inside of part 33 so that the thin
33 middle area is flush with the bottom border of the Instrumentation Unit.

Glue the second spacer 33 around the lower section of part 34.
34

33

9 Instrumentation Unit Former

Glue the formers 35b into the Instrumentation Unit. One former sits on
the stage connection assembly and the other one at or near the top of
35b
the unit.

35b
10 Body Assembly
41a 41
Roll the main body tube 32 into a cylinder and glue together using
connector strip 32a.
35
As it is a very long cylinder, you may want to cut it in half vertically and
glue together again after making the cylinders. In this case, you should
make your own connector strip. For added stability, you may also want
to use the formers 32a.
32
Then, stick the Instrumentation Unit 35 into the top of the cylinder and
the Propulsion section into the bottom. Be careful with the glue so that
it doesnt squeeze out of the connection.

The small recessed ring of the connection pieces must remain visible
1 between the three tube segments.

Finally, form the capsule adapter 41, glue together using connector
strip 41a and glue on top of the instrumentation unit.

11 Antennas

Glue antenna 39 to the same shaped marking on the instrument

sections.

Cut four antenna bases 36 and glue to the circle marks on the IU -
watch for the correct color - there are two black and two white parts.

Cut out four parts 40 and glue to the base and IU as shown in the
39 40 diagram. You may also make these antennas from wire, using the
36
template on page P1.

Finally, glue part 37 onto the white area of part 38 and glue to the
rectangular mark near the bottom of the IU.

37
38

12 Mercury Capsule Crew Compartment

42c

Roll the crew compartment skin 42 into a cone and glue together using
the connection strip 42a.

42 Close the cone at the top with former 42c and at the bottom with 42b.

42a

42b
13 Mercury Capsule Recovery Compartment

43b Form the recovery compartment 43 into a cylinder and glue together
using connection strip 43a.

43 Close the cylinder at the top using former 43b.

43a
If you want extra stiffness, you can produce a second copy of part 43b
and also close the recovery compartment at the bottom.

14 Aero Wedge
44b
Form the aero wedge, part 44 into a ring and glue together.
44
Close the wedge at the top using former 44b.

15 Antenna Fairing
46a 46 Form the antenna fairing 45 and glue together using connector strip
45b
45a. Close the cone at the top with former 45b.

If you want a former at the bottom of the fairing as well, you can
produce a copy of part 44b and cut out only the inner white portion
45a 45
minus a little material for paper thickness.

Next, form the nose cone using part 46 and connector strip 46a.

Glue the assembly to the top of the aero wedge former, fitting into the
white area of the former.
16 Details: Clamp Ring Cover, Umbilical Fairings

First, glue the Clamp Ring cover 47 around the base of the crew
compartment. Start at a marking for an umbilical fairing, that way it isnt
visible later should the clamp ring cover be a bit short.

Cut out the three umbilical fairings 48, round them carefully and glue
together as shown in the image. Cut out parts 49 and glue to the middle
of the fairings.

Next, glue the fairings to the capsule at the three marked positions so
48 49 that they cover the clamp ring.
47
Cut out six Clamp Ring Cover Pulley Dampers 50 and glue to the
markings at the top of the interstage as shown in the image.

50

17 Escape Engine Casing

51b Roll the casing skin 51 into a cylinder and glue together using
connector strip 51a.

Close the cylinder at the top using former 51b and at the bottom with
part 51c.
51a

51

51c

18 Escape Engine Details

Form part 54 into a cone and glue to the bottom of the engine casing.
Make sure the seam is in the same position as on the casing.
52
Cut the rings 52 and 53 and glue around the cylinder.
58
Cut out two umbilical electrical wire casings, carefully round the wider
areas that will go between the rings to form a half-round casing and
53
glue to the engine casing on opposite sides. One casing should cover
the seam, the other one goes to the opposite side.
57
Cut a piece of wire to length using the probe template and stick it into
the center of the top engine former. Form a tiny cone from part 57 and
glue to the top of the wire.
54
19 Escape Engine Nozzles

Form part 56 into a cylinder and glue to the center circle mark of the
engine mount.

Form truncated cones from parts 55 and glue to the other circle marks
so that the nozzles point outward.

You may want to color the insides of the nozzles black.

56
55

20 Escape Tower

Cut out part 59 and parts 60. Glue parts 60 onto the white areas of part
59.

Then fold the assembly so that it looks like the top view diagram.

Alternatively, you can print page P1 onto transparency and only cut out
the outer shape of the tower. That may be easier for some of you.

59

60 Top View

21 Escape Tower - Final Assembly

Glue the escape engine between the vertical struts of the escape tower.
Make sure the escape motor nozzles fit nicely between the angled
struts.

Finally, glue the escape tower to the Mercury capsule. The struts are
glued to the small area of the former that closes the aero wedge.

Orient the tower in such a way that one of the vertical struts is in line
with the seams on the rocket.

Congratulations, your Mercury Redstone MR-3 model is finished.

1 inch
1 cm

13
6 7 8

3
14
4
9 9

15

17 17

16

18

19 20 21 21
9 9 17 17
Laminate on cardboard to a total thickness of approx. 0.5-0.8 mm
C

35 37

38 40
C C C C
C C

5 41 42
1b 32b 32b

11
10 22 22

C1
1 inch
1 cm

U U
N N
I I 12 12

T T
E E
D D
12 12

34

S S
33 33

39 43

T T
36

31

A A
23 28
24 30
29

T T 25 28
29 30
31

E E 25
28
31

S S 25
29 30

31
28
29 30
C C C 25
MR MR MR MR MR
7 7 7 7 7 32

C2
1 inch
1 cm

26 26 26 26 27 27 27 27

36 37 38
39

50
40

41
47

35

42
46
7 OM

49
D
EE
FR

48
44

43 45

Laminate on cardboard to a total thickness of approx. 0.5-0.8 mm

43b 42c 44b

C
C C

51c 45b
42b 51b
35b 35b

C3
1 inch
1 cm
53

52
56
54

51

57
58

55

60
59

C4
1 inch
1 cm

Antenna Template Probe Template

51a
1a

43a

45a

Escape Tower template - print on transparency

if you dont want to cut out all the struts

35a

41a

42a

46a

32a
P1