Octet truss drill template

Use a template for drilling holes in octet truss, to ensure that all holes are the same and identically located. Print on paper first,then trace or laminate onto cardboard and punch hole centers per template guides. Provided octet truss welding work is standard, dimensional tolerance of ±1 mm is achievable. Square face bolted connection is 20×20 cm, with holes of sufficient tolerance for no. 17 bolts. Drill templates are here in PDF: octet truss face jointoctet truss face joint -alt (print to A4 size sheet).

octet truss face joint20140910_124607-MOTION copy 220140910_124650-MOTION copy 220140910_124644_15198270395_o20140910_151612_15013174610_o

Spacecraft . octet truss fabrication process

Fabrication of a semi-octet truss using 1 or 1-1/2 inch mild steel angle bar requires use of several jigs: 2d truss jigsquare pyramid jig, and spacers for setting flat bar and holding string line to gauge top angle bar when welding. Each truss comprises 16 square pyramids of 4 pcs 10 or 12 mm by 16.85 cm iron rods welded to a linear array of 19.6 cm flat bar straps set in a 1 or 1-1/2 inch ms angle bar frame 20 cm wide by 282.5 cm long.

Welding: Tack weld first throughout to assemble octet truss, then complete full weld once all metal elements are held in contact. Usually a small amount of grinding required to clear sharp edges. Apply hardener coat to seal and spray 3-6 coats of automotive paint. Paint damage possible (e.g. scratches) during transport and assembly; paint touch-up work may be done after assembly.

2 weld octet truss 1-MOTION

3 weld octet truss 2-MOTION

4 weld octet truss 3-MOTION

amp_octet truss_template

To assembly a semi-octet truss, you will need: 2d truss jig and square pyramid jig.

amp_octet truss_template2 amp_octet truss_template3 amp_octet truss_template4 amp_octet truss_template5 amp_octet truss_template6 amp_octet truss_template7 amp_octet truss_template8 amp_octet truss_template9 amp_octet truss_template10 amp_octet truss_template11 amp_octet truss_template12 amp_octet truss_template13

Spacecraft . box truss assembly


deck_box_truss-1 deck_box_truss-2 deck_box_truss-3 deck_box_truss-4

deck_box_truss-0

tack weld outer frame of 2d truss in jig then use spacer to precisely set out 1in flat bar lengths.
tack weld outer frame of 2d truss in jig then use spacer to precisely set out 1in flat bar lengths.
tack weld 1in flat bar lengths either side to 2d truss frame.
tack weld 1in flat bar lengths either side to 2d truss frame.

on flat and level ground surface, weld pair of 2d trusses together with 1-1/2in angle bar at top and bottom corners.on flat and level ground surface, weld pair of 2d trusses together with 1-1/2in angle bar at top and bottom corners.

Finally, weld diagonal struts for cross-bracing.
Finally, weld diagonal struts for cross-bracing.

5 box truss floor raft

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