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Level Three Construction Page

The fincan

The fin fillets

The payload section

The removable electronics bay

The heavily reinforced fins

A small picture of the booster

Parts List

-Two 6" PML phenolic airframes laminated with Kevlar sock and two layers of 2oz fiberglass.

-One 98mm PML phenolic motor mount tube

-One 6" phenolic coupler reinforced with one layer 4.8oz Kevlar and two layers of 9oz fiberglass.

-One PML nosecone, FNC-6.00 (24" long fiberglass nose cone)

-Three 1/8" clipped delta G10 fins, laminated with one layer of 4.8oz Kevlar, and three layers of 5oz carbon fiber

-Three ½" 98mm to 6" centering rings

-Four bulkheads: two body tube, two coupler.

-One length of 7/16" all thread rod

-Two forged 7/16" eye-nuts and washers. (Recovery points and closures on electronics bay)

-Three 7/16" nuts

-Six 8-32 tee nuts and screws (For holding electronics bay in place)

-Two 10-24 tee nuts and screws (For motor retention) 

-Two ¼" u-bolts

-Two 30' lengths of 1" tubular nylon for recovery harness

-Four 1500lb quick links

-Two 600lb quick links

-One nomex chute protector

-One nomex deployment bag

-One drogue parachute

-One Rocketman R-14C parachute

-One blacksky Altacc

-One Olsen M2 altimeter and mounting hardware

-Four terminal blocks

-Four ¾" copper tubing caps (For ejection canister)

-Four ejection charges of black powder

-Four Daveyfire 28br electric matches

-Two blacksky aluminum rail guides

 

Overview

A.Airframe

The rocket is twenty calibers long with three clipped delta fins. The trailing edges of the fins are angled forward to help avoid landing damage. The rocket is a pretty straightforward simple design. The airframe tubes are 6" Public Missiles phenolic tubing covered with a layer of Kevlar sock and two layers of 2oz fiberglass. Most of the construction was done with Bob Smith 30 minute and 2 hour epoxy.  The 98mm motor mount is attached to the airframe with three centering rings, which are bonded to the airframe. The fins are 1/8" G10 laminated with Kevlar and carbon fiber to reduce the possibility of fin flutter and landing damage. They are attached to the motor mount tube with 2 hour epoxy and strips of Kevlar.  Once the fin fillets have been applied, a layer of fiberglass will be laminated from fin-tip to fin-tip across the intervening airframe for strength.

 

B. Recovery System 

The recovery system attachments use U-bolts and 1500lb. quick links. The bulkheads are all ½" "aircraft" birch plywood. All the recovery harnesses are 1" tubular Nylon. The deployment system will use black power charges to pressurize the airframe and deploy the parachutes. Drogue recovery uses a 36'' chute and main recovery uses a Rocketman R14C 'chute.

  

C.  Avionics

Primary electronics will be the blacksky Altacc, backup will be an Olsen Advanced Electronics M2 altimeter. Each unit has its own separate apogee and main ejection charges. The M2 altimeter will be programmed to fire its apogee charge 1.75 seconds after it senses apogee in order to reduce the chances of both charges going off at the same time. The drogue will be released at apogee and the main will be released at 1,000' with the backup firing at 600'. DaveyFire 28br matches will be used to ignite the black powder charges. The electronics are placed in a PML 6" coupler reinforced with Kevlar and fiberglass. The 6"x12" coupler will be secured in the upper 6"x48" payload bay with six 8-32 blind nuts and screws. Four bulkheads (two coupler BH's, and two body tube BH's) will be glued into two 'caps' that will seal off the electronics bay. A 7/16" threaded rod will run through the whole length of the coupler with forged eyebolts at the ends to hold the 'caps' together and serve as recovery connection points

 

D. Motor

The motor of choice for my TRA Level three flight will be an Aerotech M1315. I will be using a motor adapter to use the 75mm motor in my 98mm motor mount. It basically consist of 75mm motor tube with three 75mm to 98mm centering rings epoxied in place with a 75mm 6" centering ring at the end for negative retention. For positive retention two metal brackets will be used to keep the motor from kicking out of the adapter. Two tee-nuts were mounted behind the bottom centering ring of the rocket in order to anchor two screws that will be holding the metal brackets in place, as well as the motor and adapter. To ignite the motor, a dipped electric match with thermolite and strips of Blue Thunder propellant should do the trick.

 

F. Launcher

The rocket will be fitted with blacksky Research ProRail guides and can be launched from a standard ProRail. Two aluminum guides will be used: one at the rear of the rocket and one about 30" above the bottom one. The guides will be secured with two screws that run through the airframe and through a 2"x2" piece of 16 gauge steel contoured to the airframe backed with nuts. These anchor points were then covered with epoxy and sanded smooth. This will eliminate the chance of the recovery harness getting caught up on the backing on the upper rail guide.     

 

G. Stability

Unloaded, the rocket has 3.6 calibers of stability. With the M1315 motor install the rocket has 2.4 calibers of stability. These calculations were simulated in Rocksim but will be double checked prior to flight with the loaded rocket.