Do we need to adjust the dimensions of the aluminium insert in order to account for the 0.1mm gap required? Or do you simply push the CF tube onto the insert and hope that it stretches over some of the glass beads as you slide it on? The ID of the CF tube is 182mm and the aluminium insert is meant to be machined to max 181.985mm min 181.956mm (it's an H7g6 fit). Apologies for what is probably a really simple question but none of us have any practical composite experience. I imagine we'll have to make the aluminium insert have a 179.8mm diameter but then that gives alignment issues as the whole structure is about 3m long and the insert is at the base so if they're not quite concentric it will be very noticeable at the top.

In order to obtain permission to launch this we need to submit a detailed report showing that it will stay within a given distance of the launch site and remain in one piece even in the worst case scenarios. The documentation requires going into all the details about how the adhesives will be used.