The model employs my usual skin-on-tube building technique. The vehicle's "skins" are designed on computer or constructed out of paper, and then affixed to appropriately sized model rocket tubes. I was able to find tubes that were extremely close to the dimensions of the solid rocket motors and Cryogenic First Stage, so I lucked out on that score.

In an attempt to save the time and expense it would take to built a whole new rocket, the CaLV will use elements of the shuttle's Space Transportation System. A modified and longer External Tank will be used as the Core Stage, and a lower structure will be added to contain the four or five rocket motors. Two 5-segment Reusable Solid Rocket Motors will be used to provide more thrust at lift-off.

This model was built based on some of the early artists' renderings of the CaLV, and as you might imagine, the design has changed since they were released. The most noticeable change has been to increase the diameter of the Core Stage fuel tank from 27.5 feet to 33 feet. The reason this is being done is because NASA had originally planned on using the Space Shuttle Main Engine (RS-25) as the Core Stage Engine (CSE), but in mid-May, it decided to use the RS-68 -- as used on the Delta IV -- instead. Also, the diameter of the payload shroud is now not as large as originally intended.

With those changes in mind, here's my card model of the "original" design. It is built using card "skin" wrap-arounds on appropriately sized model rocket tubes, with plenty of scratchbuilding. I used a ridged paper that I found at an art supply store to replicate the spray-on insulation of the Core Stage. The paper was painted the ET's rusty color, then lightly sanded to remove paint from the taller ridges. A different type of ridged paper to represent the vertical corrugated intertank sections. Several different colors of card stock were used throughout.

Image: Side perspective

Image: Booster nose

Image: Rocket detail

Image: Engine detail

Image: With a cousin