Due to the extremely time consuming nature of building the fusealge pod, it's construction was started while other tasks were being done that didn't require the vacuum system. The pod is the heart of the model, holding the engine, wing, cargo, and radio components together. Last year's pod had an inner layer of 5 oz Kevlar, and skin matrix of 1/8" balsa, and an outer shell of 5 oz carbon fibre. It was stronger than hell, 2.5 lbs, and could be used as a deadly weapon if needed. When the model crashed onto its nose during flight trials from a altitude of about 150 ft, the pod was almost completely undamaged (the balsa between the outer and inners layers split, which was easily repaired with a little C/A and accelerator). This year the goal was lightness, without costing too much in strength. The pod construction uses the "lost foam" method, where a foam blank is laminated in material, then dissolved out with acetone to leave the finished shell. Nice and easy, if a little time consuming.
Above Middle: Here you can see how the belcrank is only added to one of the two vertical fins. Rudder servos will be added to both fins. Framing has begun on the second of two rudders.
Above Right: A finshed rudder, showing standard stringer construction. The bottom brace has an allowance for mounting the control horn. The tail surfaces will eventually be covered in transparent Ultracote, and all hinges made with the material to prevent air gaps in the hingeline.
