AV Bay part 1:
The objectives for the AV Bay are to support dual-deployment and some "fun" add-ons. I've built and tested an Eggtimer Quantum with a telemetry module, and would also like to fit a small camera (RunCam Split 3 Light) and two LiPo batteries. I also got a pull-pin switch from
LabRat Rocketry because having a big 'Remove Before Flight' tag seemed like a cool idea and I'd like the camera to start recording at power-on on the rail.
I'm not contemplating redundancy for the charges or the altimeter at this time. However, I suppose the motor ejection could provide redundancy for the drogue.
I printed up some bulkheads in order to play with placement and fittings - each bulkhead has to mount a charge well and through bulkhead terminals, a u-bolt for attaching recovery and a 1/4" threaded rod to hold the module together. The parts are printed in PET-CF.
My concern is that the bay is really heavy - right now without a sled, electronics or batteries its ~300g. Did I overbuild it? There isn't one thing I can point at as the problem. If I remove the 4 large metal bars tying the U-bolt to the threaded rod I could save some weight, and if I went to an aluminium threaded rod I could save some more. The former introduces some risk if the bulkhead fails badly, the latter might be an option but doesn't gain much.
Also, how do people shock-test thier bays? I attached the forward end to my basesment ceiling with 2' of Kevlar, then attached 10lbs of weight to the aft with another 2' of Kevlar and dropped it a few times. It all held together, but I don't know how valid a test that is.
Thoughts and feedback welcome!