We've made a video which we hope will explain things further. Be sure to read below for more information and pictures.
The majority of the work has been organising the layout of the components within the payload and making compartments inside the box to offer them extra protection and insulation. Basically we need everything to fit nice and snug! Here come the photos:
|Drilling a hole for the camera lens with a hole cutter.|
We tested a few options based on recommendations by other HABers for cutting out this aperture, such as using metal cookie cutters or just cutting it freehand. This method however gave us the cleanest finish. The cookie cutter method proved particularly tricky as our polystyrene has a closed cell structure. This is the property that makes it waterproof in case it lands in the world's deepest muddy puddle or the English Channel etc. It is therefore very dense and resilient to cookie cutter pressure!
|A spot of hoovering.|
|Freehand trimming was easiest with a fine hacksaw blade.|
|Layer 1 - the base of the payload.|
|A quick weigh of the payload.|
|Layer 2 in the making.|
|Our tracker and battery pack in position. |
The space on the right is to secure the GoPro in position.
The hole in the middle is for the aerial.
|The tracker's nice and snug.|
|Layer 2 in situ.|
With all of our components housed and layers completed, we decided our payload box had approximately 2" of excess height. When we originally designed the box, we opted for a cube mainly for ease/it seemed pretty logical, and well you have to start somewhere don't you? Now in hindsight this extra polystyrene was an unnecessary weight so we trimmed it off.
|Things get a little nervy as we measure |
what's about to get the chop.
|The moment of truth. With an upturned dust bin lid acting as a polystyrene dust receptacle. Resourceful.|
|Bye bye extra weight.|
|Our new low profile design being sanded.|
|Time to make it a hat.|
|Our double layer lid being glued together.|