--- /dev/null
+# Freedom Flies
+
+This was Bdale's first dual deploy airframe.
+
+## Motivation
+
+After successful L1 and L2 certs, Bdale wanted to try his hand at a full
+custom high power aiframe, and chose the
+[PerfectFlite](http://www.perfectflite.com/)
+[MAWD](http://www.perfectflite.com/catalog/MAWD.html) commercial recording
+altimeter to make this a dual deployment system.
+
+## Design Details
+
+* 75mm phenolic air frame
+* 38mm BSD cardboard motor mount
+* [Giant Leap](http://giantleaprocketry.com/) old-style 75mm nose cone
+* 1/16 inch G10 fins in a custom shape, with rounded edges, cut from surplus
+ printed circuit board material.
+* 3/8 inch birch plywood centering rings and bulkheads, CNC milled, the two
+ that hold the fins are notched for perfect fin alignment.
+
+## Build
+
+## Publicity
+
+## Flights
+
--- /dev/null
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--- /dev/null
+<html><head><meta http-equiv="Content-Type" content="text/html; charset=ISO-8859-1"><title>Goblin 10</title><meta name="generator" content="DocBook XSL Stylesheets V1.73.2"></head><body bgcolor="white" text="black" link="#0000FF" vlink="#840084" alink="#0000FF"><div class="book" lang="en"><div class="titlepage"><div><div><h1 class="title"><a name="id2481338"></a>Goblin 10</h1></div><div><h2 class="subtitle">A NAR L3 Certification Rocket</h2></div><div><div class="author"><h3 class="author"><span class="firstname">Bdale</span> <span class="surname">Garbee</span></h3></div></div><div><p class="copyright">Copyright © 2008 Bdale Garbee</p></div><div><div class="legalnotice"><a name="id2736747"></a><p>
+ This document is released under the terms of the
+ <a class="ulink" href="http://creativecommons.org/licenses/by-sa/3.0/" target="_top">
+ Creative Commons ShareAlike 3.0
+ </a>
+ license.
+ </p></div></div><div><div class="revhistory"><table border="1" width="100%" summary="Revision history"><tr><th align="left" valign="top" colspan="2"><b>Revision History</b></th></tr><tr><td align="left">Revision 1.0</td><td align="left">15 November 2008</td></tr><tr><td align="left" colspan="2">Successful certification flight at Hudson Ranch</td></tr><tr><td align="left">Revision 0.2</td><td align="left">28 October 2008</td></tr><tr><td align="left" colspan="2">Revising during flight to DC</td></tr><tr><td align="left">Revision 0.1</td><td align="left">23 October 2008</td></tr><tr><td align="left" colspan="2">Initial content, derived from YikStik</td></tr></table></div></div></div><hr></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="chapter"><a href="#id2744045">1. Introduction</a></span></dt><dt><span class="chapter"><a href="#id2749934">2. Design</a></span></dt><dd><dl><dt><span class="section"><a href="#id2759790">Overview</a></span></dt><dt><span class="section"><a href="#id2737277">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2763689">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2744686">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2754969">Nose Cone Electronics Bay</a></span></dt><dt><span class="section"><a href="#id2733689">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2763384">Avionics</a></span></dt><dt><span class="section"><a href="#id2740504">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2748086">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2767164">Recovery System</a></span></dt></dl></dd></dl></dd><dt><span class="chapter"><a href="#id2768933">3. Construction Details</a></span></dt><dd><dl><dt><span class="section"><a href="#id2749141">Airframe</a></span></dt><dt><span class="section"><a href="#id2754017">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2771414">Avionics Bay</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2745741">4. Recovery Systems Package</a></span></dt><dd><dl><dt><span class="section"><a href="#id2740673">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2752914">Recovery Initiation Control Components</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2748101">5. Checklists </a></span></dt><dt><span class="chapter"><a href="#id2750187">6. Flight Summary</a></span></dt><dt><span class="chapter"><a href="#id2764884">7. Analysis and Conclusions</a></span></dt></dl></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2744045"></a>Chapter 1. Introduction</h2></div></div></div><p>
+ This is a rocket I'm building for my second attempt at a NAR Level 3
+ certification flight. It's basically a Polecat Aerospace Goblin 10 kit
+ augmented with an additional electronics bay in the nose cone, some
+ structural reinforcement, and incorporating a few personal build
+ preferences.
+ </p><p>
+ Preliminary analysis suggests that it should reach just under 7k feet
+ on the Aerotech M1297W reload, and could break two miles on the
+ Cesaroni M795W moon-burner. This means that a certification flight can
+ be supported at Hudson Ranch with the standing 8k waiver, at the Tripoli
+ Colorado site under their higher-altitude window, or at either of the
+ NCR launch sites under their standing waivers.
+ The smallest reasonable motor for this rocket would be a Cesaroni
+ K445 or equivalent, which would yield an apogee of about 2300 feet.
+ </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2749934"></a>Chapter 2. Design</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2759790">Overview</a></span></dt><dt><span class="section"><a href="#id2737277">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2763689">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2744686">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2754969">Nose Cone Electronics Bay</a></span></dt><dt><span class="section"><a href="#id2733689">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2763384">Avionics</a></span></dt><dt><span class="section"><a href="#id2740504">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2748086">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2767164">Recovery System</a></span></dt></dl></dd></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2759790"></a>Overview</h2></div></div></div><p>
+ The Goblin 10 kit is a simple "four fins and a nose cone" rocket
+ that is short and squat, with a 98mm motor mount.
+ It supports dual-deploy by
+ using the forward end of the long motor mount tube to hold the main.
+ The primary electronics bay is between the forward two motor mount
+ centering rings, accessed by a side hatch. An additional payload bay
+ will be built inside the nose cone to carry experimental altimeters,
+ a tracking beacon, and possibly a GPS position reporting system.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2737277"></a>Rocksim File</h2></div></div></div>
+ This is the current working design in Rocksim format:
+ <a class="ulink" href="Polecat_Goblin_10.rkt" target="_top"> Polecat_Goblin_10.rkt </a></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2763689"></a>Drawing from Rocksim</h2></div></div></div><span class="inlinemediaobject"><img src="Polecat_Goblin_10.jpg" height="450"></span></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2744686"></a>Motor Retention</h2></div></div></div><p>
+ I will include 8-24 T-nuts in the aft centering ring spaced to allow
+ the use of an Aeropack 98mm retainer and associated 75mm adapter.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2754969"></a>Nose Cone Electronics Bay</h2></div></div></div><p>
+ Instead of using the supplied nose cone bulkhead, I intend to cut a
+ custom one that would support installing a length of 98mm motor mount
+ from the tip of the nose to the bulkhead. With a plate cut to cover
+ the aft end of the airframe tube, this would form an electronics bay
+ capable of holding a beacon transmitter, GPS system, or other custom
+ electronics.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2733689"></a>Electronics</h2></div></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2763384"></a>Avionics</h3></div></div></div><p>
+ The recovery system will feature dual redundant barometric altimeters
+ in the main avionics bay between the two forward motor mount
+ centering rings.
+ </p><p>
+ A PerfectFlite MAWD will be flown as the primary altimeter and to
+ record the flight altitude profile.
+ A MissileWorks Mini-RRC2 will fly as backup altimeter and to
+ directly capture max velocity.
+ </p><p>
+ Each altimeter will have a separate battery and rotary power switch.
+ A third rotary switch will be used as a SAFE/ARM switch configured
+ to interrupt connectivity to all ejection charges in accordance with
+ NAR certification requirements.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2740504"></a>Stability Evaluation</h3></div></div></div><p>
+ The Goblin 10 kit designers indicate
+ that the rocket is unconditionally stable with all motors that fit
+ the motor mount geometry. Since we're adding mass at both ends, by
+ putting a payload in the nose cone and by glassing the fins, the
+ overall stability of the design should be retained, but simulation
+ to confirm that seems prudent.
+ </p><p>
+ Thorough analysis using
+ <a class="ulink" href="http://www.apogeerockets.com/rocksim.asp" target="_top">
+ RockSim
+ </a>
+ with various motors ranging from the Cesaroni K445 through the
+ Aerotech M1939W always shows the stability as marginal.
+ This is typical of short fat rockets that don't meet normal length
+ to airframe diameter ratio expectations.
+ Given this, I take the fact that RockSim shows the stability as
+ marginal instead of unstable as strong evidence that the rocket
+ will in fact be stable in flight.
+ I also note that the simulated margin of stability
+ in my as-built configuration is fairly close to the margin of
+ stability of the as-designed model.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2748086"></a>Expected Performance</h3></div></div></div><p>
+ The Aerotech M1297W reload should carry this vehicle to just under
+ 7000 feet AGL from Colorado Front Range launch sites. It
+ should reach just over 2 miles on a Cesaroni M795 moon burner
+ or equivalent.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2767164"></a>Recovery System</h3></div></div></div><p>
+ The recovery system will use dual redundant barometric altimeters
+ firing 4F black powder charges using commercial e-matches.
+ At apogee, a drogue chute will deploy with separation of the nose
+ cone. A Giant Leap TAC-1 36 inch chute already in hand will serve
+ as the drogue.
+ At a preset altitude, a main chute will be deployed from the forward
+ end of the motor mount tube to achieve recovery of the bulk of the
+ rocket at approximately 20 ft/sec.
+ </p><p>
+ I intend to sew the main parachute from scratch with my wife's help
+ using a design documented by
+ <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
+ Team Vatsaas
+ </a>
+ using 1.9oz rip-stop nylon and 550 lb parachute cord. The anticipated
+ build weight implies that a 10 foot parachute would be appropriately
+ sized.
+ </p><p>
+ The recovery system attachment points will all use 1/4 inch u-bolts
+ with nuts, washers, and backing plates through bulkheads.
+ </p></div></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2768933"></a>Chapter 3. Construction Details</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2749141">Airframe</a></span></dt><dt><span class="section"><a href="#id2754017">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2771414">Avionics Bay</a></span></dt></dl></div><p>
+ I have collected all of my
+ <a class="ulink" href="http://gallery.gag.com/rockets/goblin10" target="_top">
+ build photos
+ </a>
+ in one place, they may show better than I can explain how various
+ aspects of the Goblin went together.
+ </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2749141"></a>Airframe</h2></div></div></div><p>
+ The airframe tubing provided in the Polecat kit is thick cardboard tube
+ with a thin exterior fiberglass wrap. To increase airframe strength,
+ and particularly to prevent zippers, additional reinforcement seemed
+ warranted.
+ </p><p>
+ The inner layer of paper was removed from the front 9" or
+ so of the tube. The tube was soaked with West Systems epoxy diluted
+ with about 20% by volume with acetone, and then a carbon fiber wrap was
+ applied to the interior front of the tube and held in place during
+ curing by an inflatable child's bounce toy inside a plastic garbage
+ bag. The result is a substantially strengthened tube, with carbon
+ fiber lining from the leading edge back past the first centering ring.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2754017"></a>Nose Cone</h2></div></div></div><p>
+ The provided nose cone bulkhead was replaced by a custom centering
+ ring cut from 3/8 inch birch plywood. The ring's outer diameter was
+ adjusted put place the ring approximately an inch forward of the end
+ of the motor mount tube, and the inner diameter was cut to fit Giant
+ Leap 98mm phenolic airframe tubing. A length of such tubing was cut
+ to fit inside the nose cone and extend back to flush with the trailing
+ edge of the ring. The centering ring was drilled and fitted with two
+ u-bolts for recovery system attachment and four 6-32 T-nuts to hold
+ a payload mounting plate in place over the aft end of the 98mm tube.
+ </p><p>
+ The airframe tubing was glued into the tip of the nose cone with West
+ Systems epoxy using both milled glass and microlite filler to thicken
+ the mix. The centering ring was then epoxied in place using a similar
+ mix around the outer edge to form a heavy fillet and 5-minute epoxy to
+ the piece of airframe tubing. After the epoxies cured, a rotary tool
+ was used to cut the airframe tubing off flush with the aft surface of
+ the centering ring.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2771414"></a>Avionics Bay</h2></div></div></div><p>
+ The avionics bay walls were installed approximately 90 degrees apart
+ prior to installation of the motor mount assembly in the airframe.
+ The airframe wall was marked for a 3.5 x 6.5" access hatch centered
+ over the bay 90 degrees from the rail button line. This allows
+ sufficient room to install the switches on one side of the hatch yet
+ still inside the bay, and to place the static vent on the other side
+ of the hatch so that there will be minimal effect from air disturbed
+ by movement over the hatch cover edges.
+ </p><p>
+ Rails were fabricated from 3/8" birch plywood and 6-32 blind nuts to
+ allow for a removable avionics sled, rectangular, with 4 screws to
+ hold the sled in place.
+ A suitably sized avionics sled should be possible to install and remove
+ through the avionics bay hatch allowing for possible future experiments
+ with alternative avionics.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2745741"></a>Chapter 4. Recovery Systems Package</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2740673">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2752914">Recovery Initiation Control Components</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2740673"></a>Recovery System Description</h2></div></div></div><p>
+ This rocket uses dual deployment.
+ </p><p>
+ The apogee event separates the nose cone from the
+ airframe. The nose cone is attached to the airframe with a length
+ of heavy-duty tubular nylon shock cord. A drogue chute protected
+ during ejection by a kevlar blanket is attached to the shock cord
+ close to the nose cone end.
+ </p><p>
+ The main is a 10 foot chute sewn from the design documented by
+ <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
+ Team Vatsaas.
+ </a>
+ It is held in place prior to ejection by a layer of paper taped over
+ the front of the motor mount tube. At ejection, a piston pushes the
+ chute forward through the paper and ejects it from the rocket.
+ This chute is attached to the airframe through an additional length of
+ heavy-duty tubular nylon shock cord.
+ </p><p>
+ Depending on the results of ground testing, the main chute may be
+ packed in a Giant Leap kevlar deployment bag attached at the main
+ chute apex, with a smaller drogue chute deployed to pull off the bag
+ and cleanly deploy the main. The primary motivation for this is to
+ prevent the main chute shrouds from tangling during ejection.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2752914"></a>Recovery Initiation Control Components</h2></div></div></div><p>
+ The main avionics bay between the forward two centering rings is
+ populated with two commercial altimeters, a PerfectFlite MAWD
+ and a Missile Works miniRRC2.
+ Each is powered by a dedicated 9V alkaline battery, and has a
+ dedicated on/off power switch mounted for access from outside the
+ rocket. Additionally, a single safe/arm switch with two poles is used
+ to interrupt the return circuits from the igniters to each altimeter.
+ See the attached schematic of the avionics bay contents for more
+ details.
+ </p><p>
+ Details of ejection charge design goes here.
+ </p><p>
+ The
+ <a class="ulink" href="http://www.info-central.org/recovery_powder.shtml" target="_top">
+ Info Central Black Powder Sizing
+ </a>
+ page is the most authoritative site I've found on this topic.
+ The formula they suggest is diameter in inches squared times
+ length in inches times a coefficient in grams of black powder.
+ For the main charge, which will be in the 98mm motor mount tube, a
+ pressure of 15psi is appropriate giving a coefficient of 0.006.
+ For the drogue charge, which will be in the main airframe, a
+ pressure of 5psi is more appropriate, leading to a coefficient
+ of 0.002.
+ </p><p>
+ The drogue bay is 10 inches ID at the widest point, but contains
+ the protrusion of the main bay and a decreasing radius in the
+ nose cone. Thus some fudging on the length is appropriate, and
+ we will use 18 inches. That works out to 3.6 grams of BP. This
+ rocket will not fly high enough for there to be a significant
+ effect on BP burn characteristics, so no special compensation
+ should be required.
+ </p><p>
+ The main bay is 3.9 inches ID and perhaps as much as 24 inches long
+ depending on which motor is selected.
+ That works out to 2.2 grams of BP.
+ </p><p>
+ Ground testing yielded 3.5 grams for the apogee charge and 1.5 grams
+ for the main.
+ Backup charges will contain additional BP in accordance
+ with the "blow it off or blow it up" philosophy.
+ </p><p>
+ With a 10 foot Team Vatsaas design parachute and our
+ anticipated build weight, the descent rate under main
+ should be just over 20 feet per second.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2748101"></a>Chapter 5. Checklists </h2></div></div></div><div class="orderedlist"><ol type="1"><li>
+ Planning
+ <div class="orderedlist"><ol type="1"><li>
+ Pick a club launch with suitable waiver and facilities to
+ support flight.
+ </li><li>
+ Confirm L3CC member(s) available to attend selected launch.
+ </li><li>
+ Confirm that required loaner motor hardware will be available at launch.
+ </li><li>
+ Notify launch sponsor (club president) of intended flight.
+ </li><li>
+ Notify interested friends of intended flight.
+ </li><li>
+ Perform final pre-flight simulation with as-built masses, etc.
+ </li><li>
+ Gather consummables and tools required to support flight
+ <div class="orderedlist"><ol type="1"><li>
+ fresh 9V batteries
+ </li><li>
+ black powder
+ </li><li>
+ e-matches
+ </li><li>
+ motor retainer and adapter parts
+ </li><li>
+ small nylon wire ties
+ </li><li>
+ cellulose wadding material
+ </li><li>
+ masking tape
+ </li><li>
+ screwdriver for phillips-head avionics bay screws
+ </li><li>
+ small straight-blade screwdriver for power switches
+ </li><li>
+ motor reload kit (or arrangements to procure at launch)
+ </li><li>
+ high temperature grease
+ </li><li>
+ long small diameter dowels for igniter insertion
+ </li></ol></div></li></ol></div></li><li>
+ Before Leaving Home
+ <div class="orderedlist"><ol type="1"><li>
+ program altimeters for suitable mach delay and recovery deployment
+ <div class="itemizedlist"><ul type="disc"><li>
+ MAWD
+ <div class="itemizedlist"><ul type="circle"><li>
+ no mach delay
+ </li><li>
+ 1300 foot main deploy
+ </li></ul></div></li><li>
+
+ miniRRC2
+ <div class="itemizedlist"><ul type="circle"><li>
+ no mach delay
+ </li><li>
+ 1000 foot main deploy
+ </li><li>
+ 2 seconds apogee delay
+ </li><li>
+ no main delay
+ </li><li>
+ dual deploy
+ </li><li>
+ ops mode 16 (default)
+ </li></ul></div></li></ul></div></li><li>
+ assemble all recovery system components and ensure everything fits
+ </li><li>
+ confirm wiring and operation of altimeter power and safe/arm
+ switches
+ </li><li>
+ Ground test recovery system to confirm suitable black powder
+ charge sizing
+ </li></ol></div></li><li>
+ Pre-Flight
+ <div class="orderedlist"><ol type="1"><li>
+ confirm payload batteries in good condition, bay loaded,
+ power switch works
+ </li><li>
+ confirm reception of signals from transmitter(s)
+ </li><li>
+ install fresh 9V batteries for altimeters on avionics bay sled
+ </li><li>
+ inspect altimeters and associated avionics bay wiring for
+ visible faults
+ </li><li>
+ close up avionics bay
+ </li><li>
+ build and install BP charges
+ <div class="orderedlist"><ol type="1"><li>
+ Drogue Primary Charge - 3.5 grams 4F BP
+ </li><li>
+ Drogue Backup Charge - 4.0 grams 4F BP
+ </li><li>
+ Main Primary Charge - 1.5 grams 4F BP
+ </li><li>
+ Main Backup Charge - 2.0 grams 4F BP
+ </li></ol></div></li><li>
+ fold main chute, connect recovery harness to piston and airframe,
+ install in MMT and tape paper over the front end
+ </li><li>
+ fold drogue chute into a kevlar pad, connect recovery harness to
+ nose cone and airframe, install in airframe
+ </li><li>
+ power up payload using switch on base plate in nose cone, then
+ install nose cone, using masking tape to adjust fit as required
+ </li><li>
+ safely power up altimeters, operate safe/arm switch,
+ and confirm e-match continuity
+ </li><li>
+ safe and power-down the altimeters
+ </li><li>
+ load motor per manufacturer instructions
+ </li><li>
+ install motor in motor mount
+ </li><li>
+ install motor retention
+ </li><li>
+ prepare igniter using e-matches, 1/8 inch dowel
+ </li><li>
+ confirm all screws in place, avionics off and safe
+ </li><li>
+ fill out a launch card
+ </li><li>
+ notify RSO/LCO of readiness for inspection and launch, obtain
+ a rail assignment and permission to move rocket to launch pad for
+ final prep
+ </li><li>
+ coordinate readiness with support team members, photographers,
+ observers
+ </li></ol></div></li><li>
+ Final Prep
+ <div class="orderedlist"><ol type="1"><li>
+ move rocket to launch area
+ </li><li>
+ clean and lubricate launch rail if necessary
+ </li><li>
+ confirm reception of signals from payload transmitter(s)
+ </li><li>
+ mount rocket on launch rail, rotate to vertical
+ </li><li>
+ power up primary altimeter, confirm expected beep pattern
+ </li><li>
+ power up backup altimeter, confirm expected beep pattern
+ </li><li>
+ arm ejection charges
+ </li><li>
+ confirm altimeters both giving expected beep patterns for
+ igniter continuity
+ </li><li>
+ install igniter and connect to launch control system
+ </li><li>
+ capture GPS waypoint for rail location
+ </li><li>
+ smile for the cameras, make sure we have enough "foil Murphy!"
+ shots taken
+ </li><li>
+ retreat to safe area behind LCO
+ </li><li>
+ confirm continued reception of transmitter signal(s) from
+ payload bay
+ </li><li>
+ confirm photographers and observers are ready and know what to
+ expect
+ </li><li>
+ make sure binoculars and backpack with water and recovery tools
+ are at hand
+ </li><li>
+ tell RSO and LCO we're ready to launch
+ </li><li>
+ try to relax and enjoy watching the flight!
+ </li></ol></div></li><li>
+ Recovery
+ <div class="orderedlist"><ol type="1"><li>
+ track rocket to landing site
+ </li><li>
+ capture GPS waypoint of landing site, take lots of photos
+ </li><li>
+ note any damage
+ </li><li>
+ gather up and roughly re-pack recovery system for return to
+ flight line
+ </li><li>
+ bring the rocket to observers for post-flight inspection
+ </li></ol></div></li></ol></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2750187"></a>Chapter 6. Flight Summary</h2></div></div></div><p>
+ A successful level 3 certification flight occurred on 15 November 2008
+ at the SCORE Hudson Ranch launch facility. The motor was an Aerotech
+ M1297W provided by Tim Thomas of Giant Leap Motors, the igniter was
+ assembled by James Russell using his special thermite mixture, and
+ numerious SCORE, COSROCS, and NCR members were present to assist with
+ the launch! Great weather for November... mostly clear and sunny,
+ light winds, dry ground, temps above freezing.
+ </p><p>
+ The motor came up to pressure very quickly and the rocket leapt off
+ the pad, climbing smoothly under power and then doing about two slow
+ rolls during the coast phase. Deployment of the nose cone and drogue
+ occurred as planned when the primary apogee charge fired.
+ Unfortunately, the main deployed around the time the backup apogee
+ charge fired, so the descent was under main from apogee. Fortunately,
+ the winds were low enough and the descent rate high enough that the
+ rocket touched down without damage within the waiver area for a
+ successful certification!
+ </p><p>
+ The rocket weighed 25.2 pounds prepared for launch without the motor.
+ The motor weighed about 10.25 pounds, which included about 6 pounds
+ of propellant. Thus the descent mass under chute was just over 29
+ pounds.
+ The miniRRC2 altimeter reported 5949 feet apogee, 980 feet per second
+ max velocity, and 19 seconds to apogee. The MAWD reported 5953 feet
+ apogee.
+ </p><div class="itemizedlist"><ul type="disc"><li><a class="ulink" href="http://picasaweb.google.com/jamesr2/StealeyMemorialLaunchSiteHudsonRanch" target="_top">
+ Photos of the launch taken by James Russell
+ </a></li><li><a class="ulink" href="http://cosrocs.org/all%20other%20videos/2008videos/11-15hudson/bdale_L3.mov" target="_top">
+ Video of the launch taken by Jeff Lane
+ </a></li><li><a class="ulink" href="http://www.youtube.com/watch?v=xaJnl89wfWU" target="_top">
+ Video of the launch taken by Jason Unwin
+ </a></li></ul></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2764884"></a>Chapter 7. Analysis and Conclusions</h2></div></div></div><p>
+ The ascent was straighter than expected... very smooth during
+ the motor burn, then a couple slow rolls during coast. The two
+ altimeters agreed within 4 feet on the apogee. The max
+ velocity recorded is a little higher than predicted by simulation,
+ but the accuracy of that measurement is likely limited since it is
+ based on pressure data.
+ </p><p>
+ I was able to watch the apogee events through binoculars, and could
+ clearly see the main deploy as the backup apogee charge fired. I saw
+ some evidence of tearing of the paper taped over the motor mount to
+ retain the main chute during ground testing, so assume this was the
+ root cause of the early deployment. When the backup apogee charge
+ fired, the shock cord was not yet in tension, and thus the charge
+ probably kicked the airframe backwards hard enough to allow the main
+ chute to slide out through the torn paper and deploy. The best fix
+ for this might be
+ to fabricate a second piston to use as a cap and retain it with two
+ shear pins. This would be much less likely to prematurely deploy than
+ the current taped paper approach.
+ </p><p>
+ The most significant variance from expectation was the descent rate.
+ The spreadsheet provided by the Team Vatsaas folks for their design
+ suggested we'd see around 21 feet per second. Analysis of the flight
+ profile from the MAWD shows that our actual descent rate was about
+ 32 feet per second. There are three possible sources of error to
+ consider.
+ </p><div class="orderedlist"><ol type="1"><li>
+ The first is descent mass. Pre-flight calculations used
+ 25 pounds.
+ The actual flight weight was 25.2 pounds plus the burn-out
+ weight of the M1297W, which should be about 4.5 pounds.
+ That yields 29.5 pounds total. All pre-flight calculations
+ were done using 25 lbs, with the thought that the motor mass
+ might cancel out against the drag provided by the drogue.
+ In flight, it appeared the drogue supported the nose and the
+ main supported the fin can with very little interaction between
+ the two.
+ </li><li>
+ Second, the dimensions given by Team Vatsaas' spreadsheet
+ for the pattern grid seem small. For a 10 foot chute, they
+ suggest a grid size of 5 inches, which looks more like an 8.5
+ foot finished chute size to me.
+ </li><li>
+ Finally, the Cd in the spreadsheet is 1.5, which may be overly
+ optimistic.
+ </li></ol></div><p>
+ My calculations show that if we assume a chute size of 8.5 feet and
+ a Cd closer to 1, we can get to a descent rate of 32 feet per second.
+ </p><p>
+ So, overall, this was a successful flight, but with three things to
+ change before we fly the airframe again...
+ </p><div class="orderedlist"><ol type="1"><li>
+ the main chute may be too small
+ </li><li>
+ switch to a piston to cap the main chute bay
+ </li><li>
+ beef up the battery retention on the avionics sled
+ </li></ol></div><p>
+ </p></div></div></body></html>
--- /dev/null
+# BSD Horizon
+
+This was Bdale's first high power airframe.
+
+## Motivation
+
+This is the airframe the earned Bdale his L1 and L2 certifications.
+
+## Design Details
+
+* 98mm BSD cardboard air frame
+* 38mm BSD cardboard motor mount
+* 1/8 inch G10 fins
+* 1/4 inch birch plywood centering rings and bulkhead
+
+## Build
+
+## Publicity
+
+## Flights
+
--- /dev/null
+# Horizon Rebuild
+
+This is an improved redesign and rebuild of Bdale's first high power airframe.
+
+## Motivation
+
+The airframe that earned Bdale his L1 and L2 certifications was severely
+damaged after the nylon strap portion of the recovery harness failed at
+altitude during a flight at the NCR North launch site. The nose cone, payload
+bay, and parachute were recovered on the day. The fin can turned up later
+in the weekend after Bdale had to leave, and was returned a few weeks
+later. Only the nose cone, fins, and rail buttons from the original airframe
+survive in this rebuild.
+
+This rebuild is configured with a 54mm motor mount and electronics bay capable
+of dual deployment with redundant electronics.
+
+## Design Details
+
+* 98mm Giant Leap DynaWind air frame
+* 54mm Giant Leap phenolic motor mount
+* 1/8 inch G10 fins, recycled from [Horizon](../Horizon)
+* 3/8 inch birch plywood centering rings and bulkheads
+
+## Build
+
+## Publicity
+
+## Flights
+
+++ /dev/null
-## Basic Data ##
-
-### When Built ###
-### Who Built It ###
-### Rocksim Model ###
-### CNC Files ###
-### Photos ###
-
-## Objectives ##
-## Special Techniques ##
-## Observations ##
-## List of Flights ##
-
-[[!tag tags/rockets]]
--- /dev/null
+# No Nukes
+
+## Motivation
+
+Bdale's wife Karen bought an air brush and asked for a rocket to paint. Bdale
+scrounged the parts pile and threw this rocket together very quickly. This is
+a simple single-deploy rocket for motor based ejection.
+
+## Design Details
+
+* 98mm [Giant Leap](http://giantleaprocketry.com) phenolic air frame
+* 38mm phenolic motor mount
+* 6-32 t-nuts for Kaplow clips
+* MadCow Rocketry [98mm nose cone](http://www.madcowrocketry.com/servlet/Detail?no=74), though we debated using the [Giant Leap](http://giantleaprocketry.com/) Pinnacle 98mm nose cone, which would also be a good choice
+* 1/4 inch birch plywood fins, upscaled from the LOC Lil Nuke
+* 3/8 inch birch plywood centering rings and bulkheads, CNC milled, the two
+ that hold the fins are notched for perfect fin alignment.
+
+## Build
+
+Construction occurred during September 2009.
+
+## Publicity
+
+## Flights
+
+First flown at NCR's Oktoberfest 2009, on a Cesaroni Pro38 2-grain Imax
+motor. This was my first use of a Pro38 grain spacer to fly this reload
+in my 3-grain case. It was a beautiful flight, but the airframe acquired
+a lengthy zipper at deployment.
--- /dev/null
+# BSD Thor 3"
+
+A kit that caught Bdale's eye.
+
+## Motivation
+
+## Design Details
+
+* 75mm BSD cardboard air frame with full-length coupler
+* 38mm BSD cardboard motor mount
+* 1/4 inch birch plywood fins
+* 1/4 inch birch plywood centering rings and bulkheads
+
+## Build
+
+## Publicity
+
+## Flights
+
+Not yet flown.
--- /dev/null
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+</SimulationEventList>
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+<Material>Polycarbonate</Material>
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+<DensityType>0</DensityType>
+<PartNo>Pinnacle 3.90</PartNo>
+<PartDesc>3.90 in. Pinnacle Nosecone</PartDesc>
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+<AbientColor>blue</AbientColor>
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+<LaunchGuideAzimuthUncertainty>0.</LaunchGuideAzimuthUncertainty>
+<LaunchGuideElevationUncertainty>0.</LaunchGuideElevationUncertainty>
+<IgnitionUncertainty>0.</IgnitionUncertainty>
+<CATOUncertainty>0.</CATOUncertainty>
+<DeploymentUncertainty>0.</DeploymentUncertainty>
+<RecoveryDeviceUncertainty>0.</RecoveryDeviceUncertainty>
+<SimulationName>[J330-None] </SimulationName>
+<VelocityAtLaunchGuideEnd>16.8513</VelocityAtLaunchGuideEnd>
+<WindStartAltitude>0.</WindStartAltitude>
+<TimeToWindShear>0.</TimeToWindShear>
+<TimeToFreeFlight>0.31375</TimeToFreeFlight>
+<TimeToMaxVelocity>2.06875</TimeToMaxVelocity>
+<TimeToMaxAcceleration>0.05</TimeToMaxAcceleration>
+<Nsims>10</Nsims>
+<CalcResolution>1</CalcResolution>
+<SamplesPerSecond>800.</SamplesPerSecond>
+<SimulationType>0</SimulationType>
+<LocationDataServerName>Earth</LocationDataServerName>
+<LocationDataServerDisplayName>Standard earth condistions.</LocationDataServerDisplayName>
+<ExecutionTime>2.163</ExecutionTime>
+<RangeAtLanding>-102.858</RangeAtLanding>
+<DirectionAtLanding>0.</DirectionAtLanding>
+<VelocityAtLanding>92.8518</VelocityAtLanding>
+<XVelcoityAtLanding>-5.21285</XVelcoityAtLanding>
+<YVelocityAtLanding>-92.7053</YVelocityAtLanding>
+<ZVelocityAtLanding>0.</ZVelocityAtLanding>
+<StageSeparationTime>0,0,0,0,0</StageSeparationTime>
+<StageEjectTime>-1,-1,-1,-1,-1</StageEjectTime>
+<TimeToDeployment>0,0,0,0,0</TimeToDeployment>
+<DeploymentType>32,32,32,32,32</DeploymentType>
+<SamplesPerSecondDescent>1.</SamplesPerSecondDescent>
+<CalculationFlags>1</CalculationFlags>
+<Mass0>6.552</Mass0>
+<CG0>1.7289</CG0>
+<LaterialMOI0>4.15113</LaterialMOI0>
+<RadialMOI0>0.0152822</RadialMOI0>
+<GUID>{4a48823c-7fc2-48b1-b2a3-30db719aa598}</GUID>
+<Booster1Staging>
+<SimulationEvent>
+<PartSerialNo>0</PartSerialNo>
+<Type>0</Type>
+<DeployAltitude>0.</DeployAltitude>
+<DeplyTime>0.</DeplyTime>
+<HasDeployed>0</HasDeployed>
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+<DeployedAt_Velocity>0.</DeployedAt_Velocity>
+<DeployedAt_Range>0.</DeployedAt_Range>
+<DeployedAt_Time>0.</DeployedAt_Time>
+<DeviceID>-1</DeviceID>
+<TestType>0,0,0</TestType>
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+<TestValueDegrees>0,0,0</TestValueDegrees>
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+<Booster2Staging>
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+<TestValueTime>0,0,0</TestValueTime>
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+</Booster2Staging>
+<SimulationEvents>
+<SimulationEvent>
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+<Type>1</Type>
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+<DeployedAt_Range>0.</DeployedAt_Range>
+<DeployedAt_Time>0.</DeployedAt_Time>
+<DeviceID>-1</DeviceID>
+<TestType>28,28,28</TestType>
+<TestCondition>0,0,0</TestCondition>
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+<TestValueDegrees>0,0,0</TestValueDegrees>
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+<TestValueMach>0,0,0</TestValueMach>
+<TestValueTime>0,0,0</TestValueTime>
+<TestValueQ>0,0,0</TestValueQ>
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+<SimulationEvent>
+<PartSerialNo>18</PartSerialNo>
+<Type>1</Type>
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+<DeployedAt_Range>0.</DeployedAt_Range>
+<DeployedAt_Time>0.</DeployedAt_Time>
+<DeviceID>-1</DeviceID>
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+<TestValueQ>0,0,0</TestValueQ>
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+<SimulationEvent>
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+<TestValueTime>0,0,0</TestValueTime>
+<TestValueQ>0,0,0</TestValueQ>
+</SimulationEvent>
+</SimulationEvents>
+<Stage1Engines>
+</Stage1Engines>
+<Stage2Engines>
+</Stage2Engines>
+<Stage3Engines>
+<EngineSet>
+<EngineCount>1</EngineCount>
+<EngineCode>J330</EngineCode>
+<IgnitionDelay>0.</IgnitionDelay>
+<EngineMfg>Cesaroni</EngineMfg>
+<EngineOverhang>6.35</EngineOverhang>
+<CasingCG>0.</CasingCG>
+<MountSerialNo>6</MountSerialNo>
+<EjectionDelay>-2.</EjectionDelay>
+<RotateXaboutY>0.</RotateXaboutY>
+<RotateEngineAxisAboutX>0.</RotateEngineAxisAboutX>
+</EngineSet>
+</Stage3Engines>
+</SimulationResults>
+</SimulationResultsList>
+</RockSimDocument>
--- /dev/null
+<html><head><meta http-equiv="Content-Type" content="text/html; charset=ISO-8859-1"><title>YikStik</title><meta name="generator" content="DocBook XSL Stylesheets V1.73.2"></head><body bgcolor="white" text="black" link="#0000FF" vlink="#840084" alink="#0000FF"><div class="book" lang="en"><div class="titlepage"><div><div><h1 class="title"><a name="id2322390"></a>YikStik</h1></div><div><h2 class="subtitle">A NAR L3 Certification Rocket</h2></div><div><div class="author"><h3 class="author"><span class="firstname">Bdale</span> <span class="surname">Garbee</span></h3></div></div><div><p class="copyright">Copyright © 2008 Bdale Garbee</p></div><div><div class="legalnotice"><a name="id2577753"></a><p>
+ This document is released under the terms of the
+ <a class="ulink" href="http://creativecommons.org/licenses/by-sa/3.0/" target="_top">
+ Creative Commons ShareAlike 3.0
+ </a>
+ license.
+ </p></div></div><div><div class="revhistory"><table border="1" width="100%" summary="Revision history"><tr><th align="left" valign="top" colspan="2"><b>Revision History</b></th></tr><tr><td align="left">Revision 1.2</td><td align="left">12 January 2009</td></tr><tr><td align="left" colspan="2">
+ Document firmware bug in miniRRC2 and possible impact on flight.
+ </td></tr><tr><td align="left">Revision 1.1</td><td align="left">5 December 2008</td></tr><tr><td align="left" colspan="2">
+ Remove embedded images in favor of references to gallery.gag.com
+ </td></tr><tr><td align="left">Revision 1.0</td><td align="left">28 October 2008</td></tr><tr><td align="left" colspan="2">
+ Recording results of first, and only, flight attempt.
+ </td></tr><tr><td align="left">Revision 0.5</td><td align="left">27 September 2008</td></tr><tr><td align="left" colspan="2">
+ Building checklists
+ </td></tr><tr><td align="left">Revision 0.4</td><td align="left">17 September 2008</td></tr><tr><td align="left" colspan="2">
+ Documenting the build process as it happens
+ </td></tr><tr><td align="left">Revision 0.3</td><td align="left">29 March 2008</td></tr><tr><td align="left" colspan="2">
+ Incorporate ideas from James Russell during initial L3CC review
+ </td></tr><tr><td align="left">Revision 0.2</td><td align="left">27 March 2008</td></tr><tr><td align="left" colspan="2">Cleaned up for initial review</td></tr><tr><td align="left">Revision 0.1</td><td align="left">16 March 2008</td></tr><tr><td align="left" colspan="2">Initial content</td></tr></table></div></div></div><hr></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="chapter"><a href="#id2565537">1. Introduction</a></span></dt><dd><dl><dt><span class="section"><a href="#id2565574">Why "YikStik"?</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2557207">2. Design</a></span></dt><dd><dl><dt><span class="section"><a href="#id2557213">Overview</a></span></dt><dt><span class="section"><a href="#id2557231">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2557244">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2557261">Airframe Tubing</a></span></dt><dt><span class="section"><a href="#id2557277">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2557288">Fins</a></span></dt><dt><span class="section"><a href="#id2608670">Centering Rings and Bulkheads </a></span></dt><dt><span class="section"><a href="#id2597438">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2599532">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2612550">Avionics</a></span></dt><dt><span class="section"><a href="#id2589090">Payload</a></span></dt></dl></dd><dt><span class="section"><a href="#id2581651">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2581446">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2599074">Recovery System</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2592234">3. Construction Details</a></span></dt><dd><dl><dt><span class="section"><a href="#id2599259">Airframe and Couplers</a></span></dt><dt><span class="section"><a href="#id2596433">Fins</a></span></dt><dt><span class="section"><a href="#id2606804">Centering Rings and Bulkheads</a></span></dt><dt><span class="section"><a href="#id2588775">Assembling the Booster Section</a></span></dt><dt><span class="section"><a href="#id2584973">Avionics Bay</a></span></dt><dt><span class="section"><a href="#id2606384">Payload Bay</a></span></dt><dt><span class="section"><a href="#id2607348">Recovery System</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2600260">4. Recovery Systems Package</a></span></dt><dd><dl><dt><span class="section"><a href="#id2595964">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2609782">Recovery Initiation Control Components</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2585586">5. Stability Evaluation</a></span></dt><dt><span class="chapter"><a href="#id2606777">6. Expected Performance</a></span></dt><dt><span class="chapter"><a href="#id2611290">7. Checklists </a></span></dt><dt><span class="chapter"><a href="#id2610811">8. Flight Summary</a></span></dt><dt><span class="chapter"><a href="#id2607490">9. Analysis and Conclusions</a></span></dt></dl></div><p>
+ Please note that I stopped adding photos to this document at some
+ point. I have many more photos of the YikStik build, but haven't
+ decided how best to present them yet... update coming someday!
+ </p><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2565537"></a>Chapter 1. Introduction</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2565574">Why "YikStik"?</a></span></dt></dl></div><p>
+ This is the rocket I'm designing for my NAR Level 3 certification flight.
+ The general idea is to build a fairly cheap rocket capable of reliably
+ flying this year's Aerotech level 3 special, which is an M1297W reload.
+ I'd like to be able to fly the prototype of my own altimeter design, and
+ to be able to fly it often on smaller / cheaper reloads at launch sites
+ with modest waivers like Hudson Ranch.
+ </p><p>
+ I want to experiment with vacuum bagging carbon fiber reinforcements, and
+ intend to use my CNC milling machine to cut all the centering rings, etc.
+ The new Giant Leap "Dynawind" tubing feels like a good choice, and if we
+ stick to the 4 inch version we can use a cheap plastic nosecone to keep
+ the cost down.
+ </p><p>
+ Preliminary analysis suggests that a roughly 8 foot rocket made from 4 inch
+ airframe with a 75mm mount and three fins should fly to something around
+ 14k feet on the M1297W, could break three miles on the M1850W, and yet
+ could safely fly on reloads as small as a J for economical fun. Those
+ altitudes mean the certification flight will need to be at a site with a
+ high-altitude waiver like the NCR north site.
+ </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2565574"></a>Why "YikStik"?</h2></div></div></div><p>
+ I've always thought the high-gloss red paint job on one of my son's rockets
+ when out on a launch rod in the sun looks a lot like glistening wet
+ lipstick.
+ </p><p>
+ Combine that with the fact that my wife who isn't fond of the stuff
+ refers to lipstick as "yik stick"... and the rest should be obvious.
+ </p><p>
+ My planned paint scheme is a bright red nosecone, gold tube, and black fin
+ can, which is the mental image I have of what lipstick applicators look
+ like, most likely from a stick my mother or one of my grandmothers had
+ when I was a child.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2557207"></a>Chapter 2. Design</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2557213">Overview</a></span></dt><dt><span class="section"><a href="#id2557231">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2557244">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2557261">Airframe Tubing</a></span></dt><dt><span class="section"><a href="#id2557277">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2557288">Fins</a></span></dt><dt><span class="section"><a href="#id2608670">Centering Rings and Bulkheads </a></span></dt><dt><span class="section"><a href="#id2597438">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2599532">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2612550">Avionics</a></span></dt><dt><span class="section"><a href="#id2589090">Payload</a></span></dt></dl></dd><dt><span class="section"><a href="#id2581651">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2581446">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2599074">Recovery System</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557213"></a>Overview</h2></div></div></div><p>
+ YikStik is a fairly simple "three fins and a nose cone" dual-deploy
+ rocket using a 75mm motor mount, 4 inch glass-wrapped phenolic airframe
+ with zipperless fin can, plastic nose cone, plywood fins,
+ and lots of glass and carbon fiber reinforcing.
+ The primary electronics bay will be designed to
+ hold two altimeters, and a distinct payload bay may carry an
+ experimental altimeter, GPS receiver, and downlink transmitter.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557231"></a>Rocksim File</h2></div></div></div>
+ This is the current working design in Rocksim format:
+ <a class="ulink" href="YikStik.rkt" target="_top"> YikStik.rkt </a></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557244"></a>Drawing from Rocksim</h2></div></div></div><span class="inlinemediaobject"><img src="YikStik.jpg"></span></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557261"></a>Airframe Tubing</h2></div></div></div><p>
+ I intend to cut the airframe components from two 48 inch lengths of
+ 98mm Giant Leap Dynawind tubing. The 30 inch main bay and 18 inch drogue
+ bay will be cut from one length, while the 33 inches of fin can, 2 inches
+ of electronics bay, and 8 inches of payload bay will be cut from the
+ second.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557277"></a>Nose Cone</h2></div></div></div><p>
+ I intend to use a Giant Leap "Pinnacle" 3.9 inch nose cone.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557288"></a>Fins</h2></div></div></div><p>
+ The fins are designed from scratch, and I intend to build them up from
+ two layers of 1/8 inch birch plywood, three layers of carbon fiber, and
+ two layers of 6 oz glass. The stack will be glass, carbon fiber,
+ plywood, carbon fiber, plywood, carbon fiber, glass. The edges of the
+ plywood will be routed to give a modified airfoil shape to the finished
+ fins. The stack will be laminated using West Systems epoxy products
+ and vacuum bagged.
+ The shape is a compromise between mass, surviving Mach-transition stress,
+ optimal stability margin, and avoiding damage during handling and on
+ contact with the ground during recovery.
+ </p><p>
+ The fins will be locked in to milled slots in two of the centering rings,
+ and will be epoxied to the motor mount with glass reinforcing tape.
+ The airframe will be slotted to allow the completed motor mount / fin
+ assembly to be inserted from the rear, with fillets of epoxy applied
+ inside and outside the airframe after insertion.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2608670"></a>Centering Rings and Bulkheads </h2></div></div></div><p>
+ All centering rings and bulkheads will be custom machined from 3/8 inch
+ birch plywood using my 3-axis CNC milling machine. Some rings will use
+ laminated pairs of 3/4 inch total thickness to enable use of threaded
+ inserts for 1/4-20 rail button screws or deep routing for fin alignment
+ slots.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2597438"></a>Motor Retention</h2></div></div></div><p>
+ I will embed three 8-24 T-nuts in the aft centering ring spaced to allow
+ the use of home-made Kaplow clips to retain 75mm motors.
+ The same holes may be used to attach custom motor mount adapters for
+ smaller diameter motors.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599532"></a>Electronics</h2></div></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2612550"></a>Avionics</h3></div></div></div><p>
+ The recovery system will feature dual redundant barometric altimeters
+ in an electronics bay similar to the LOC design located between the
+ drogue and main parachute bays.
+ </p><p>
+ A PerfectFlite MAWD will be flown as the primary altimeter and to
+ record the flight altitude profile.
+ A MissileWorks Mini-RRC2 will fly as backup altimeter and to
+ directly capture max velocity.
+ </p><p>
+ Each altimeter will have a separate battery and power switch. A 4PDT
+ slide switch will be used as a SAFE/ARM switch configured to interrupt
+ connectivity to the ejection charges.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2589090"></a>Payload</h3></div></div></div><p>
+ I hope to fly
+ <a class="ulink" href="http://altusmetrum.org/" target="_top">
+ my own altimeter design
+ </a>
+ as a payload in a short payload section just behind the nose cone.
+ I have acquired the pieces to add a GPS receiver and RF downlink using
+ ham radio frequencies to the payload to track the rocket's position
+ during flight.
+ This is not essential to fly,
+ but could make recovery simpler and would just be fun to fly if I can
+ get it all working and suitably ground and/or flight tested in time.
+ </p></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2581651"></a>Stability Evaluation</h2></div></div></div><p>
+ This design has been thoroughly analyzed using
+ <a class="ulink" href="http://www.apogeerockets.com/rocksim.asp" target="_top">
+ RockSim
+ </a>
+ with motors ranging from the
+ Cesaroni J285 through the Aerotech M1850W and appears to be
+ unconditionally stable across that range. The lowest margin is around
+ 1.2 seen with the M1297W planned for my level 3 certification flight,
+ albeit with many masses still only roughly estimated.
+ </p><p>
+ These simulations will be refined as the build proceeds and as-built
+ stability verified before flight.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2581446"></a>Expected Performance</h2></div></div></div><p>
+ The Aerotech M1297W reload should carry this vehicle without ballast
+ to just over 14 thousand feet AGL. It should make over 16 thousand
+ feet AGL on an M1850W, and should fly stably to roughly 2.5k feet AGL
+ on a Cesaroni J285.
+ </p><p>
+ Hitting optimal mass on the largest motors may require
+ ballast, depending on final build weight.
+ My plan is to fly without ballast on the certification flight,
+ trading some altitude for a slower and softer recovery.
+ If the cert succeeds, then I might try an optimal mass
+ flight sometime later on an M1850W or equivalent "bigger M"
+ reload to join the "three mile club".
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599074"></a>Recovery System</h2></div></div></div><p>
+ The recovery system will use dual redundant barometric altimeters firing
+ black powder charges.
+ At apogee, a drogue chute will deploy from just forward of the fin can,
+ with size selected for an approximately 100 ft/sec descent rate.
+ At a preset altitude, a main chute will be deployed to achieve recovery
+ of the bulk of the rocket at under 20 ft/sec.
+ The main chute will be packed in a deployment bag, configured as a
+ "freebag" and pulled out of the airframe by a second drogue chute. This
+ drogue will recover the nosecone and deployment bag separately from the
+ remainder of the rocket which will recover under the main.
+ </p><p>
+ I intend to sew the parachutes from scratch using a design documented by
+ <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
+ Team Vatsaas
+ </a>
+ using 1.9oz rip-stop nylon and 550 lb parachute cord.
+ If time runs short, equivalent chutes from SkyAngle,
+ Rocketman, or Giant Leap could be substituted (at significantly higher
+ cost).
+ </p><p>
+ The deployment bag will probably be purchased from Giant Leap. The
+ recovery harness will probably use tubular kevlar, also from Giant Leap.
+ </p><p>
+ The recovery system attachment points will all use 1/4 inch u-bolts with
+ nuts, washers, and backing plates through bulkheads except for the fin
+ can. The fin can has insufficient room between the motor mount and
+ the airframe inner wall for nuts and washers, so an alternative means of
+ recovery system attachment is required. The fin can will be equipped
+ with either a 3/16 inch stainless steel aircraft cable loop, or a loop
+ of 1/2 inch tubular kevlar, bonded to the motor mount.
+ If available, a screw-eye attached to the forward motor closure may be
+ used instead of or in addition to this recovery attachment loop.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2592234"></a>Chapter 3. Construction Details</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2599259">Airframe and Couplers</a></span></dt><dt><span class="section"><a href="#id2596433">Fins</a></span></dt><dt><span class="section"><a href="#id2606804">Centering Rings and Bulkheads</a></span></dt><dt><span class="section"><a href="#id2588775">Assembling the Booster Section</a></span></dt><dt><span class="section"><a href="#id2584973">Avionics Bay</a></span></dt><dt><span class="section"><a href="#id2606384">Payload Bay</a></span></dt><dt><span class="section"><a href="#id2607348">Recovery System</a></span></dt></dl></div><p>
+ I have collected all of my
+ <a class="ulink" href="http://gallery.gag.com/rockets/yikstik" target="_top">
+ build photos
+ </a>
+ in one place, they may show better than I can explain how various
+ aspects of YikStik went together.
+ </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599259"></a>Airframe and Couplers</h2></div></div></div><p>
+ The tubing for the airframe, couplers, and motor mount was all cut
+ using a carefully aligned and adjusted power mitre saw, and the ends
+ lightly sanded to remove rough spots.
+ The main and drogue bays were cut from one 48 inch length of Giant
+ Leap 98mm Dynawind tubing, the fin can, electronics bay, and payload
+ bay were cut from the second. The three couplers for the fin can,
+ electronics bay, and payload bay were cut from Giant Leap 98mm phenolic
+ coupler stock. And the motor mount was cut from Giant Leap 75mm
+ phenolic airframe stock.
+ Note that the motor mount is the longest piece because of
+ the zipperless design with full-length motor mount.
+ </p><p>
+ The airframe tubing selected includes a wrap of 10oz glass in epoxy
+ over the base phenolic tubing (visible in some photos as a
+ shine on the outside of the tubing),
+ but the coupler stock is unreinforced.
+ To ensure the couplers can handle the anticipated loading, I reinforced
+ each with one layer of interior carbon fiber, using the "kitchen
+ vacuum bagging" technique documented by
+ <a class="ulink" href="http://www.jcrocket.com/kitchenbagging.shtml" target="_top">
+ John Coker.
+ </a>
+ </p><p>
+ This was my first hands-on experience working with carbon fiber. The
+ end of the coupler nearest the unit during bagging experienced some
+ crushing of the fibers right at the end. It doesn't matter for this
+ project because each of the couplers will have at least one end fitted
+ with a bulkhead or centering ring, but in the future I'll be tempted
+ to cut the coupler stock a bit long before bagging and trim to length
+ after reinforcing to get "perfect" ends. The technique worked
+ marvelously otherwise, and the resulting couplers look and should work
+ great!
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2596433"></a>Fins</h2></div></div></div><p>
+ Six pieces of 1/8 inch birch plywood were stacked, edge-aligned on what
+ would be the fin root edge, and clamped. The outline of the fin design
+ was marked in pencil, and three 1/8 inch holes drilled through the
+ stack inside the fins to allow using 4-40 screws and nuts to hold the
+ blanks together while making the initial cuts, so that they would all be
+ matched in size. The clamps were removed to avoid interference
+ during cutting. The fin outline was then cut using a radial arm saw.
+ </p><p>
+ A router table with 1/8 inch
+ roundover bit was then used to round over the outer edge, 3 blanks on
+ one side and three on the other. This edge might have been left square,
+ but I prefer the look and feel of rounding. The router table with a 1/2
+ inch diameter straight cutting bit and a fin beveling jig was used
+ to impart a 10-degree bevel on the leading and trailing edge of each fin
+ blank, again 3 on one side and three on the other. The resulting 6
+ blanks thus form 3 pairs of fin components with a modified
+ airfoil shape.
+ </p><p>
+ The fin assembly started with a simple lamination of two layers of ply
+ sandwiching a layer of carbon fiber. Each fin used "one pump" of West
+ Systems epoxy and the stack was vacuum bagged using the Foodsaver with
+ wide bagging material. To keep everything flat while the epoxy cured,
+ the stack of fins was sandwiched between two unused extra shelves for
+ a storage cabinet I had on hand
+ (particle board covered in laminate, very
+ flat and smooth, nearly inflexible at this loading), and stacked with
+ about 75 lbs of loose barbell weights.
+ </p><p>
+ On one of the three fins, the plywood layers are out of alignment by
+ 1-2mm in the longest axis. The other two are nearly perfect. Light
+ sanding should allow me to match them before laminating the outer layers
+ of carbon fiber and glass.
+ </p><p>
+ After the fins cured, they were bulk sanded with medium and fine
+ sandpaper and an electric palm sander. Final sanding of the leading
+ and trailing edges was done using 400 grit paper on a flat surface,
+ holding the fin the way you'd sharpen a knife against a stone. The
+ results seem good, all three fins match pretty closely.
+ </p><p>
+ A fin holding jig was cut from 1/8" hardboard using my rotary tool
+ with a fiber cutoff wheel. The fin slots were made to be a snug fit.
+ A small batch of epoxy was used to apply a bead to the root edge and
+ tab at the leading edge, then the fins were installed against the
+ motor mount and locked into place with the jig to cure. The centering
+ ring that locks the aft edge of the fins was dry-fit during this
+ operation to ensure proper alignment, but was not glued yet. It will
+ go on after the airframe and internal fin filets are installed.
+ </p><p>
+ The fins were reinforced with fiberglass and epoxy. Masking tape was
+ used to carefully delineate where the airframe ID will be, then 6oz
+ glass 14.25" by 3.5" was epoxied fin-fin across the MMT. Strips of
+ 8.6oz "boat tape" fiberglass were worked into the joints with more
+ epoxy, and a sheet of plastic covered by ziplog bags of water were
+ used to hold things in place during the initial curing. The three
+ sides were done one at a time and allowed to cure before proceeding.
+ The results look good, and in combination with internal and external
+ airframe filets should yield a super-strong fin can.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2606804"></a>Centering Rings and Bulkheads</h2></div></div></div><p>
+ Pairs of 3/8 inch birch plywood blanks were laminated using Titebond
+ wood glue and clamped while curing to form 3/4 inch blanks for centering
+ rings. From a strength perspective, 3/8 inch should suffice, but there
+ are two reasons for going with thicker blanks in some places. The first
+ is that the rail buttons chosen use 1/4-20 mounting screws, and threaded
+ inserts in that size are nearly 3/8 inch outside diameter
+ (and thus would
+ tear up a ring only 3/8 inch thick on insertion). The second is that I
+ like to mill slots in the centering rings on each end of the fins to
+ "lock" the fins into position. Doubling the blanks used to cut those
+ rings will allow me to cut 1/4 inch deep fin slots and still have a half
+ inch of unmolested wood in the rings for strength.
+ </p><p>
+ The aft centering ring and the one just aft of the zipperless
+ coupler section were edge-drilled for the installation of brass
+ 1/4-20 threaded inserts to hold rail buttons. The inserts were
+ locked in place with epoxy, then ground down until nothing protruded
+ beyond the OD of the ring.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2588775"></a>Assembling the Booster Section</h2></div></div></div><p>
+ The forward two centering rings were installed on the MMT using
+ JB Weld high-temperature epoxy, and incorporating an aircraft cable
+ loop for recovery system retention since there just wasn't room for
+ u-bolts.
+ </p><p>
+ The ring at the leading edge of the fins was initially installed
+ assuming the aft ring would be nearly flush with the rear of the MMT
+ and equipped with Kaplow-clip style retainers, but before the fins
+ were installed a Giant Leap Slimline Tailcone Retainer for 75mm motor
+ in 98mm airframe became available thanks to Tim Thomas, and so this
+ ring was cut out and replaced with another one inch farther forward
+ to allow installation of the tailcone at the rear of the MMT. I
+ really like the tailcone on my Vertical Assault kit, and think it'll
+ work out to be a great addition for this rocket!
+ </p><p>
+ An alignment jig for the fins was carefully marked out and then cut
+ from 1/8 inch hardboard using my rotary tool and abrasive cutoff wheel.
+ The fins were then epoxied at the root and short leading edge to the
+ motor mount tube and into the slots in the forward centering ring,
+ and held rigidly aligned by the jig until the epoxy set. The fins
+ were then masked at what would be the ID of the airframe tube, and
+ reinforced with 6oz glass fin-fin across the motor mount tube between
+ each fin pair, further reinforced with strips of 1 inch glass "boat
+ tape" at each fin root joint.
+ </p><p>
+ The airframe tubing section was carefully marked for fin slots, which
+ were then cut using my rotary tool with abrasive cutoff wheel. Epoxy
+ was applied ahead of the center two rings as the frame was slid into
+ place, and the frame left standing upright until the epoxy set to
+ hopefully form ring-fin fillets on those two rings. The interior
+ fin to airframe joints were reinforced one fin at a time using West
+ Systems epoxy will milled glass as a filler. A long 3/8" dowel was
+ used to place and smooth these interior filets. The aft centering ring
+ was installed by pouring West Systems epoxy in the three fin-fin gaps,
+ placing the ring, then standing the airframe up to allow the epoxy to
+ flow over the forward surface of the ring and into the gaps between it,
+ the motor mount, and the airframe tubing. After it set, the booster
+ was placed nose-down, the airframe gaps behind the fins were taped,
+ and more epoxy was applied to seal the aft of the ring to the tubes.
+ Before this epoxy set, JB Weld was used to glue the tail cone retainer
+ in place on the MMT.
+ </p><p>
+ The exterior fin to
+ airframe joints were filleted using 5-minute epoxy thickened with
+ baby powder and smoothed with the tip of a plastic spoon, which I
+ learned about building the Vertical Assault kit. Gives great results,
+ and allowed all 6 joints to be done in one session. The space
+ above the top surface of the forward centering ring and between the
+ motor mount and zipperless-design coupler tubing was filled with epoxy
+ and milled glass. Minor gaps in the airframe behind each fin were
+ filled with epoxy clay.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2584973"></a>Avionics Bay</h2></div></div></div><p>
+ The avionics bay contains the two commercial altimeters used to
+ record information about the flight and deploy the drogue and main
+ recovery systems. It is constructed of a piece of Giant Leap 98mm
+ coupler tubing reinforced with an interior wrap of vacuum-bagged
+ carbon fiber, and a 2 inch length of Giant Leap 98mm DynaWind airframe
+ tubing.
+ </p><p>
+ The bulkheads are custom-milled from 3/8 inch birch plywood
+ milled so that about 3/16" fits inside the coupler and the remainder
+ seals the end of the coupler and just fits inside the airframe. Each
+ bulkhead has a u-bolt for attaching the recovery harnesses, and dual
+ CPVC end caps as ejection charge holders with screw terminal blocks
+ from Missile Works to attach the igniters. Two lengths of 1/4 inch
+ all-thread with nuts and washers tie the bulkheads together, with
+ wing-nuts used on one end to allow for easy disassembly.
+ </p><p>
+ A sled was fabricated to hold the altimeters and batteries. It
+ consists of 1/8 inch birch ply laminated with 6oz fiberglass on each
+ side, epoxied to cardboard tubes taken from the packaging for Aerotech
+ igniters that slide over the all-thread, further reinforced with nylon
+ ties at each end. The tubes are staggered one on either side so that
+ the sled goes right up the center of the airframe tubing.
+ </p><p>
+ Two "centering rings" containing three each 6-32 threaded inserts are
+ epoxied inside the bay to provide hard points for attaching the
+ airframe tubes for the drogue and main recovery bays. The inside
+ diameter of these rings is notched for the avionics sled, and thus
+ these rings also provide physical support for the sled.
+ </p><p>
+ Three rotary switches from Missile Works are installed through the
+ short airframe tubing section, drilled such that they end up
+ essentially flush with the outside of the airframe, clamp the coupler
+ tubing, and project inside the bay. Two are wired as SPST switches
+ for power to the two altimeters, the third is wired as a DPST switch
+ that open-circuits the igniters for the required "safe/arm" function
+ called for in the NAR L3 certification requirements.
+ </p><p>
+ The wiring of the avionics bay is documented in the attached
+ schematic diagram. Connectors were used to allow each bulkhead and
+ the switches in the housing to be quickly detached from the sled.
+ The connectors are 9-pin D shells for the switch wiring, and 4-pin
+ Molex connectors like those used on older PC hard drive power cables
+ for the bulkheads. To allow use of a single switch pole for the
+ safe/arm function for each altimeter, the two igniters attached to
+ each altimeter are safed by interrupting the common return lines as
+ shown in the schematic.
+ </p><p>
+ Sizing the static port for the avionics bay was done by applying the
+ formulas suggested by PerfectFlite and Missile Works for their
+ respective altimeter products, then comparing the results with each
+ other and with information found on the web. I've personally had
+ better luck with single ports than with multiple holes, perhaps because
+ I've been working with relatively small rockets. Regardless, I'm
+ sticking with what I know and will use a single static port hole here.
+ </p><p>
+ The measured dimensions
+ of the avionics bay as constructed are 95mm ID and approximately 250mm
+ between bulkheads. This works out to 108.73 cubic inches before
+ accounting for the volume of the sled, electronics, and wiring and
+ other components inside the bay. By the PerfectFlight formula, the
+ static port should be 0.221 inches in diameter. By the Missile Works
+ formula for a bay over 100 cubic inches the answer is 0.261 inches.
+ The closest standard drill size, which happens to split the difference,
+ is 0.250 inches. Easy enough!
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2606384"></a>Payload Bay</h2></div></div></div><p>
+ The construction of the payload bay is very similar to the avionics
+ bay, except that there is a hard-epoxied rear bulkhead, and only one
+ screw ring to hard-mount the nose cone. The forward end of the
+ payload bay is open to the open interior volume of the nose cone in
+ anticipation of extending downlink antennas above the carbon fiber
+ reinforcement in the coupler and into the nose cone, since carbon
+ fiber is opaque to RF.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2607348"></a>Recovery System</h2></div></div></div><p>
+ Pre-sewn 1/4 inch tubular kevlar harness sections were purchased
+ from Giant Leap, along with a small kevlar deployment bag and two
+ kevlar chute protectors.
+ </p><p>
+ For an apogee drogue, I plan to fly a Public Missiles 4 x 144 inch
+ nylon streamer. It will be protected with one of the kevlar blankets
+ and attached to one of the kevlar harness sections holding the booster
+ to the avionics bay.
+ </p><p>
+ The main parachute will be sewn from 1.9 oz rip-stop nylon purchased
+ from the
+ <a class="ulink" href="http://www.milloutletfabric.com/" target="_top">
+ Mill Outlet Fabric Shop
+ </a>
+ in Colorado Springs. Using the spreadsheet from
+ <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
+ Team Vatsaas
+ </a>
+ I calculate that we want an 8 foot chute to keep the airframe less
+ nose cone and payload bay below 20 feet per second at touch-down.
+ </p><p>
+ To extract the main chute and recover the nose cone and payload bay,
+ a 3 foot parachute from BSD Rocketry will be packed in a kevlar
+ blanket ahead of the main chute deployment bag, attached by kevlar
+ harness to the nose cone and payload bay assembly, and to the top of
+ the deployment bag. This assembly will recover separately from the
+ rest of the rocket.
+ </p><p>
+ The altimeters are programmed such that the MAWD fires its drogue
+ charge at apogee and its main charge at 1100 feet. The miniRRC2
+ is programmed to fire its drogue charge two seconds past apogee,
+ and its main charge at 900 feet. Thus the MAWD is primary and the
+ miniRRC2 is the backup. Since the M1297W has a burn time of about
+ 5 seconds, mach inhibit is programmed on both altimeters to 8 seconds.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2600260"></a>Chapter 4. Recovery Systems Package</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2595964">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2609782">Recovery Initiation Control Components</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2595964"></a>Recovery System Description</h2></div></div></div><p>
+ This rocket uses dual deployment.
+ </p><p>
+ The apogee event separates the
+ airframe between the zipperless-design booster section and the
+ drogue bay. These two sections are linked by a Giant Leap 20 foot
+ pre-sewn 1/4 inch tubular kevlar assembly, attached to which is a
+ Public Missiles 4 x 144 inch red nylon streamer packed in a Giant Leap
+ kevlar chute protection pad.
+ </p><p>
+ The main event separates the airframe between the forward payload bay
+ and the main bay. Attached to the nose cone and payload bay assembly
+ is a Giant Leap 15 foot pre-sewn 1/4 inch tubular kevlar assembly,
+ attached "free bag" style to the top of a Giant Leap deployment bag
+ containing the main chute. A 36 inch BSD Rocketry nylon parachute
+ packed in a Giant Leap kevlar chute protection pad serves to pull the
+ deployment bag off the main chute, after which it allows for safe
+ recovery of the nose cone and payload assembly at just under 20 feet
+ per second.
+ </p><p>
+ The 8 foot main chute is home-made from 1.9 oz rip-stop nylon using
+ the design documented by
+ <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
+ Team Vatsaas.
+ </a>
+ It is attached to the remainder of the rocket using another Giant Leap
+ pre-sewn 1/4 inch tubular kevlar assembly.
+ </p><p>
+ The anchor points are all 5/16 inch u-bolts, except for on the booster
+ which is equipped with an embedded loop of 3/16 inch stainless aircraft
+ cable. All connections are made with suitable quick-links.
+ </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2609782"></a>Recovery Initiation Control Components</h2></div></div></div><p>
+ The LOC-style avionics bay between the main and drogue bays is
+ populated with two commercial altimeters, a PerfectFlite MAWD
+ and a Missile Works miniRRC2.
+ Each is powered by a dedicated 9V battery, and has a
+ dedicated on/off power switch mounted for access from outside the
+ rocket. Additionally, a single safe/arm switch with two poles is used
+ to interrupt the return circuits from the igniters to each altimeter.
+ See the attached schematic of the avionics bay contents for more
+ details.
+ </p><p>
+ The bulkheads at each end of the avionics bay have two CPVC end caps
+ for ejection charge holders, and two-terminal screw blocks for
+ attachment of electric matches purchase from Giant Leap used to ignite
+ Goex 4F black powder ejection charges. Each charge holder and terminal
+ block pair is labelled as to main or backup since the charges will be
+ different for each.
+ </p><p>
+ The
+ <a class="ulink" href="http://www.info-central.org/recovery_powder.shtml" target="_top">
+ Info Central Black Powder Sizing
+ </a>
+ page is the most authoritative site I've found on this topic.
+ Each of the main and drogue bay interfaces will use 2 2-56 nylon screws
+ as shear pins, each of which needs 35 pounds of force or so to shear.
+ Designing for 15psi puts us between 150 and 200 pounds total force in
+ a 4 inch airframe. The formula is thus 0.006 grams times diameter
+ squared in inches times length in inches.
+ </p><p>
+ My drogue bay is 3.9 inches ID and 8 inches long, or 95.52 cubic
+ inches. That works out to about 0.73 grams. However, there will be
+ some volume in the motor mount tube above the motor that also must
+ be accounted for, enough to nearly double the total volume when flying
+ on the M1297W certification motor. Also, since this charge must fire
+ reliably at 15-18k feet above ground level of around 5k feet, such
+ that combustion is likely to be incomplete, we need to add some margin.
+ </p><p>
+ My main bay is 3.9 inches ID and about 25 inches between bulkheads,
+ or about 298.50 cubic inches. That works out to 2.28 grams.
+ </p><p>
+ Sanity checking, PerfectFlite recommends that a 4F black powder charge
+ be sized by multiplying the volume of the bay in cubic inches by 0.01
+ grams. That yields about 1.8 grams for the drogue bay and 3 grams for
+ the main bay.
+ </p><p>
+ That suggested to me that a good starting point for ground testing is
+ 1.5 grams for the drogue bay and 2.5 grams for the main bay. Ground
+ tests were done using the PC interface cable for the MAWD routed in
+ through the static test port to manually trigger ejections. Testing
+ of the apogee bay showed that 1.5 grams was sufficient for deployment
+ and 1.8 grams was more authoritative. A single test of main deploy
+ with 2.5 grams gave a nearly perfect result.
+ Given the altitude of our expected apogee, we should be generous with
+ the apogee charge, perhaps using 2.0 grams for the primary. The main
+ will deploy at an altitude below where the tests were performed, so
+ no adjustment in charge size should be required.
+ </p><p>
+ Descent rate of the nose cone and payload bay which mass just under
+ 1kg will be less than 20 feet per second with a 36 inch chute based
+ on manufacturer recommendations and Rocksim v8 simulation.
+ Descent rate of the remainder of the rocket under the 8 foot chute
+ should be about 18 feet per second by the spreadsheet provided by
+ the designers of this chute pattern, sanity checked using the descent
+ rate tables of similar commercial parachute designs, like those from
+ The Rocketman.
+ </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2585586"></a>Chapter 5. Stability Evaluation</h2></div></div></div><p>
+ Simulation using Rocksim v8 with a variety of motors showed that the
+ rocket is unconditionally stable with all motors likely to be flown.
+ The worst-case stability among 75mm motors is actually with the
+ M1297W chosen for the certification flight, at margin 1.05. This is
+ because the front of this motor falls almost exactly at the CP. Using
+ a longer motor like the M1850W raises the initial stability margin to
+ 1.10 because the front fuel grain is ahead of the CP, and lesser
+ motors also increase the stability because less mass is behind the CP.
+ The smallest motor I can conceive of flying in this rocket (a Cesaroni
+ J285) would leave us overstable with margin 3.79 on the way to about
+ 1800 feet apogee.
+ </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2606777"></a>Chapter 6. Expected Performance</h2></div></div></div><p>
+ On the certification flight, using an Aerotech M1297W reload and
+ associated hardware, the anticipated apogee is round 14,700 feet. This
+ is just under 75% of the NCR North Site standing waiver of 20,000 feet.
+ </p><p>
+ The highest altitude simulated would be achieved with an Aerotech
+ M1850W reload at nearly 18,000 feet. The lowest altitude simulated
+ is with a Cesaroni J285 and Slimline adapters to just over 1800 feet.
+ </p><p>
+ add description of anticipated flight profile here, including launch
+ weight, estimated drag coefficient, velocity leaving the rail, max
+ expected velocity, altitude, and acceleration
+ </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2611290"></a>Chapter 7. Checklists </h2></div></div></div><div class="orderedlist"><ol type="1"><li>
+ Planning
+ <div class="orderedlist"><ol type="1"><li>
+ Pick a club launch with suitable waiver and facilities to
+ support flight.
+ </li><li>
+ Confirm L3CC member(s) available to attend selected launch.
+ </li><li>
+ Confirm that required loaner motor hardware will be available at launch.
+ </li><li>
+ Notify launch sponsor (club president) of intended flight.
+ </li><li>
+ Notify interested friends of intended flight.
+ </li><li>
+ Perform final pre-flight simulation with as-built masses, etc.
+ </li><li>
+ Gather consummables and tools required to support flight
+ <div class="orderedlist"><ol type="1"><li>
+ fresh 9V batteries
+ </li><li>
+ black powder
+ </li><li>
+ e-matches
+ </li><li>
+ motor retainer snap rings
+ </li><li>
+ small nylon wire ties
+ </li><li>
+ cellulose wadding material
+ </li><li>
+ masking tape
+ </li><li>
+ screwdriver for phillips-head airframe screws
+ </li><li>
+ small straight-blade screwdriver for power switches
+ </li><li>
+ motor reload kit
+ </li><li>
+ high temperature grease
+ </li><li>
+ long small diameter dowels for igniter insertion
+ </li></ol></div></li></ol></div></li><li>
+ Before Leaving Home
+ <div class="orderedlist"><ol type="1"><li>
+ program altimeters for suitable mach delay and recovery deployment
+ <div class="itemizedlist"><ul type="disc"><li>
+ MAWD
+ <div class="itemizedlist"><ul type="circle"><li>
+ 8 seconds mach delay
+ </li><li>
+ 1500 foot main deploy
+ </li></ul></div></li><li>
+
+ miniRRC2
+ <div class="itemizedlist"><ul type="circle"><li>
+ 8 seconds mach delay
+ </li><li>
+ 1000 foot main deploy
+ </li><li>
+ 2 seconds apogee delay
+ </li><li>
+ no main delay
+ </li><li>
+ dual deploy
+ </li><li>
+ ops mode 16 (default)
+ </li></ul></div></li></ul></div></li><li>
+ assemble all recovery system components and ensure everything fits
+ </li><li>
+ confirm wiring and operation of altimeter power and safe/arm switches
+ </li><li>
+ Ground test recovery system to confirm suitable black powder
+ charge sizing
+ </li></ol></div></li><li>
+ Pre-Flight
+ <div class="orderedlist"><ol type="1"><li>
+ confirm payload batteries in good condition, bay loaded, power switch works
+ </li><li>
+ confirm reception of signals from transmitter(s) in payload bay
+ </li><li>
+ install fresh 9V batteries for altimeters on avionics bay sled
+ </li><li>
+ inspect altimeters and associated avionics bay wiring for visible faults
+ </li><li>
+ close up avionics bay
+ </li><li>
+ install e-matches, confirming resistance of 1-2 ohms and fit in charge cups
+ </li><li>
+ power up altimeters, operate safe/arm switch, and confirm e-match continuity
+ </li><li>
+ load BP charges into charge cups
+ <div class="orderedlist"><ol type="1"><li>
+ Drogue Primary Charge - 2.0 grams 4F BP
+ </li><li>
+ Drogue Backup Charge - 2.5 grams 4F BP
+ </li><li>
+ Main Primary Charge - 2.5 grams 4F BP
+ </li><li>
+ Main Backup Charge - 3.0 grams 4F BP
+ </li></ol></div></li><li>
+ connect recovery harnesses and install recovery bay airframe sections
+ </li><li>
+ power up altimeters, operate safe/arm switch, and confirm e-match continuity
+ </li><li>
+ safe and power-down the altimeters
+ </li><li>
+ load main recovery bay, attaching nosecone and payload bay assembly
+ </li><li>
+ install nylon 2-56 screws as shear pins between main bay and payload bay
+ </li><li>
+ load drogue recovery bay, feeding harness end through fin can motor tube
+ </li><li>
+ install nylon 2-56 screws as shear pins between drogue bay and fin can
+ </li><li>
+ load motor per manufacturer instructions
+ </li><li>
+ attach forged eye-bolt to forward closure if not already present
+ </li><li>
+ attach drogue harness to eye-bolt on forward motor closure
+ </li><li>
+ install motor in motor mount
+ </li><li>
+ install motor retention snap rings
+ </li><li>
+ prepare igniter for later installation by attaching to long 1/8" dowel
+ </li><li>
+ confirm all screws in place, avionics off and safe
+ </li><li>
+ fill out a launch card
+ </li><li>
+ notify RSO/LCO of readiness for inspection and launch, obtain a rail
+ assignment and permission to move rocket to launch pad for final prep
+ </li><li>
+ coordinate readiness with support team members, photographers, observers
+ </li></ol></div></li><li>
+ Final Prep
+ <div class="orderedlist"><ol type="1"><li>
+ move rocket to launch area
+ </li><li>
+ clean and lubricate launch rail if necessary
+ </li><li>
+ power up payload and confirm reception of signals from transmitter(s)
+ </li><li>
+ mount rocket on launch rail, rotate to vertical
+ </li><li>
+ power up primary altimeter, confirm expected beep pattern
+ </li><li>
+ power up backup altimeter, confirm expected beep pattern
+ </li><li>
+ arm ejection charges
+ </li><li>
+ confirm altimeters both giving expected beep patterns for igniter continuity
+ </li><li>
+ install igniter and connect to launch control system
+ </li><li>
+ capture GPS waypoint for rail location
+ </li><li>
+ smile for the cameras, make sure we have enough "foil Murphy!" shots taken
+ </li><li>
+ retreat to safe area behind LCO
+ </li><li>
+ confirm continued reception of transmitter signal(s) from payload bay
+ </li><li>
+ confirm photographers and observers are ready and know what to expect
+ </li><li>
+ make sure binoculars and backpack with water and recovery tools are at hand
+ </li><li>
+ tell RSO and LCO we're ready to launch
+ </li><li>
+ try to relax and enjoy watching the flight!
+ </li></ol></div></li><li>
+ Recovery
+ <div class="orderedlist"><ol type="1"><li>
+ track rocket to landing site
+ </li><li>
+ capture GPS waypoint of landing site, take lots of photos
+ </li><li>
+ note any damage
+ </li><li>
+ gather up and roughly re-pack recovery system for return to flight line
+ </li><li>
+ bring the rocket to observers for post-flight inspection
+ </li></ol></div></li></ol></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2610811"></a>Chapter 8. Flight Summary</h2></div></div></div><p>
+ YikStik was flown on an M1297W on Saturday morning at NCR's Oktoberfest
+ 2008. The boost was beautiful. Unfortunately, we lost visual as the
+ rocket climbed into high clouds near apogee. Radio tracking signals
+ remained strong for several minutes, then disappeared. We were
+ confused by viewing what we thought was YikStik descending before
+ signals were lost in about the right direction, but now believe we
+ were actually watching a previously launched rocket and did not see
+ YikStik descend. This confusion prevented location of any of the
+ rocket until Sunday evening, after I had left the launch area.
+ </p><p>
+ After an extensive search, the nose cone assembly was finally found
+ with the Walston tracking gear nearly 3.5 miles down range. The
+ remainder of the rocket has not been found despite extensive searching
+ on the ground and from the air.
+ </p><p>
+ Reward if returned posters were placed in the area during the week
+ following the launch but have elicited no useful reponses yet.
+ </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2607490"></a>Chapter 9. Analysis and Conclusions</h2></div></div></div><p>
+ Consideration of how the nose cone ended up where it did suggests
+ we may have had an apogee deployment of the main, perhaps due to
+ stress on the shear pins before launch, during boost, or during
+ apogee drogue deployment causing them to break early.
+ </p><p>
+ It is unfortunate that we were confused by seeing another rocket
+ descending about the expected amount of time after YikStik's launch
+ in approximately the right direction. This caused us to believe that
+ the rocket was much closer than the nose cone turned out to be, causing
+ us to waste a lot of time searching in an area too close to the launch
+ site.
+ It also caused us to assume something really weird had happened to the
+ transmitters, such that the tracking signal was suddenly lost long
+ after the rocket was on the ground, instead of what seems to really
+ have happened, which is that the rocket was farther away descending
+ after a main deployment at apogee, and the loss of signal was simply
+ due to dropping below a ridge line a couple miles from the launch site.
+ I can't help but think that if we'd been
+ looking in the right area sooner after the launch that we might have
+ found the rocket before someone else apparently picked it up.
+ </p><p>
+ I regret the decision to use a "free bag" configuration of the
+ deployment bag.
+ Since both tracking transmitters were in the payload bay behind
+ the nose cone, and we were eventually able to recover that portion
+ of the rocket, it is possible that if the deployment bag were tethered
+ to the main that we might have recovered the remainder of the rocket.
+ </p><p>
+ If the rocket is recovered and able to fly again, the two changes I
+ would like to make are to tether the deployment bag to the apex of the
+ main, and to move from 2-56 nylon screws to 4-40 nylon screws for the
+ main deployment shear pins, ensuring the holes through the airframe
+ are a loose enough fit to avoid stresses on the pins during boost. I
+ have no way to know what happened for sure, but believe this might
+ solve the assumed problem of main deployment at apogee.
+ </p><p>
+ All in all, the design and build process was educational, and a lot
+ of fun! I'm looking forward to fabricating more custom parts using
+ carbon fiber and vacuum bagging in the future.
+ The beautiful boost and obvious survival of the rocket airframe
+ through the expected mach transitions confirms my design and
+ construction skills are adequate to attain an L3 cert.
+ While I hope to recover the remainder of YikStik someday, I won't
+ waste any time before trying again with a new airframe!
+ </p><p>
+ [update] We have learned that one of the altimeters used in this
+ flight, the Missile Works miniRRC2, was subject to a fault in
+ firmware that could cause premature ejection of the main
+ in flights above 10k feet. Thus, it now seems even more likely
+ that we sustained an apogee ejection of the main, but that it
+ may well have been through no fault of the rocket's design,
+ construction, or preparation. Frustrating!
+ </p></div></div></body></html>
+++ /dev/null
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-<RadialMOI0>0.271317</RadialMOI0>
-<GUID>{d123553a-a1f0-11dd-a19e-001b247a813c}</GUID>
-<Booster1Staging>
-<SimulationEvent>
-<PartSerialNo>0</PartSerialNo>
-<Type>0</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>0</HasDeployed>
-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
-<DeployedAt_Velocity>0.</DeployedAt_Velocity>
-<DeployedAt_Range>0.</DeployedAt_Range>
-<DeployedAt_Time>0.</DeployedAt_Time>
-<DeviceID>-1</DeviceID>
-<TestType>0,0,0</TestType>
-<TestCondition>0,0,0</TestCondition>
-<TestValueAltitude>0,0,0</TestValueAltitude>
-<TestValueDegrees>0,0,0</TestValueDegrees>
-<TestValuePressure>0,0,0</TestValuePressure>
-<TestValueMach>0,0,0</TestValueMach>
-<TestValueTime>0,0,0</TestValueTime>
-<TestValueQ>0,0,0</TestValueQ>
-</SimulationEvent>
-</Booster1Staging>
-<Booster2Staging>
-<SimulationEvent>
-<PartSerialNo>0</PartSerialNo>
-<Type>0</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>0</HasDeployed>
-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
-<DeployedAt_Velocity>0.</DeployedAt_Velocity>
-<DeployedAt_Range>0.</DeployedAt_Range>
-<DeployedAt_Time>0.</DeployedAt_Time>
-<DeviceID>-1</DeviceID>
-<TestType>0,0,0</TestType>
-<TestCondition>0,0,0</TestCondition>
-<TestValueAltitude>0,0,0</TestValueAltitude>
-<TestValueDegrees>0,0,0</TestValueDegrees>
-<TestValuePressure>0,0,0</TestValuePressure>
-<TestValueMach>0,0,0</TestValueMach>
-<TestValueTime>0,0,0</TestValueTime>
-<TestValueQ>0,0,0</TestValueQ>
-</SimulationEvent>
-</Booster2Staging>
-<SimulationEvents>
-<SimulationEvent>
-<PartSerialNo>136</PartSerialNo>
-<Type>5</Type>
-<DeployAltitude>304.8</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>1</HasDeployed>
-<DeployedAt_Altitude>304.798</DeployedAt_Altitude>
-<DeployedAt_Velocity>25.4829</DeployedAt_Velocity>
-<DeployedAt_Range>-115.631</DeployedAt_Range>
-<DeployedAt_Time>85.8562</DeployedAt_Time>
-<DeviceID>128</DeviceID>
-<TestType>28,28,28</TestType>
-<TestCondition>0,0,0</TestCondition>
-<TestValueAltitude>0,0,0</TestValueAltitude>
-<TestValueDegrees>0,0,0</TestValueDegrees>
-<TestValuePressure>0,0,0</TestValuePressure>
-<TestValueMach>0,0,0</TestValueMach>
-<TestValueTime>0,0,0</TestValueTime>
-<TestValueQ>0,0,0</TestValueQ>
-</SimulationEvent>
-<SimulationEvent>
-<PartSerialNo>137</PartSerialNo>
-<Type>4</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>1</HasDeployed>
-<DeployedAt_Altitude>2044.38</DeployedAt_Altitude>
-<DeployedAt_Velocity>11.7748</DeployedAt_Velocity>
-<DeployedAt_Range>-269.999</DeployedAt_Range>
-<DeployedAt_Time>18.4363</DeployedAt_Time>
-<DeviceID>128</DeviceID>
-<TestType>28,28,28</TestType>
-<TestCondition>0,0,0</TestCondition>
-<TestValueAltitude>0,0,0</TestValueAltitude>
-<TestValueDegrees>0,0,0</TestValueDegrees>
-<TestValuePressure>0,0,0</TestValuePressure>
-<TestValueMach>0,0,0</TestValueMach>
-<TestValueTime>0,0,0</TestValueTime>
-<TestValueQ>0,0,0</TestValueQ>
-</SimulationEvent>
-</SimulationEvents>
-<Stage1Engines>
-</Stage1Engines>
-<Stage2Engines>
-</Stage2Engines>
-<Stage3Engines>
-<EngineSet>
-<EngineCount>1</EngineCount>
-<EngineCode>M1400</EngineCode>
-<IgnitionDelay>0.</IgnitionDelay>
-<EngineMfg>CTI</EngineMfg>
-<EngineOverhang>12.7</EngineOverhang>
-<CasingCG>0.</CasingCG>
-<MountSerialNo>13</MountSerialNo>
-<EjectionDelay>-2.</EjectionDelay>
-<RotateXaboutY>0.</RotateXaboutY>
-<RotateEngineAxisAboutX>0.</RotateEngineAxisAboutX>
-</EngineSet>
-</Stage3Engines>
-</SimulationResults>
-</SimulationResultsList>
-</RockSimDocument>
+++ /dev/null
-<html><head><meta http-equiv="Content-Type" content="text/html; charset=ISO-8859-1"><title>Goblin 10</title><meta name="generator" content="DocBook XSL Stylesheets V1.73.2"></head><body bgcolor="white" text="black" link="#0000FF" vlink="#840084" alink="#0000FF"><div class="book" lang="en"><div class="titlepage"><div><div><h1 class="title"><a name="id2481338"></a>Goblin 10</h1></div><div><h2 class="subtitle">A NAR L3 Certification Rocket</h2></div><div><div class="author"><h3 class="author"><span class="firstname">Bdale</span> <span class="surname">Garbee</span></h3></div></div><div><p class="copyright">Copyright © 2008 Bdale Garbee</p></div><div><div class="legalnotice"><a name="id2736747"></a><p>
- This document is released under the terms of the
- <a class="ulink" href="http://creativecommons.org/licenses/by-sa/3.0/" target="_top">
- Creative Commons ShareAlike 3.0
- </a>
- license.
- </p></div></div><div><div class="revhistory"><table border="1" width="100%" summary="Revision history"><tr><th align="left" valign="top" colspan="2"><b>Revision History</b></th></tr><tr><td align="left">Revision 1.0</td><td align="left">15 November 2008</td></tr><tr><td align="left" colspan="2">Successful certification flight at Hudson Ranch</td></tr><tr><td align="left">Revision 0.2</td><td align="left">28 October 2008</td></tr><tr><td align="left" colspan="2">Revising during flight to DC</td></tr><tr><td align="left">Revision 0.1</td><td align="left">23 October 2008</td></tr><tr><td align="left" colspan="2">Initial content, derived from YikStik</td></tr></table></div></div></div><hr></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="chapter"><a href="#id2744045">1. Introduction</a></span></dt><dt><span class="chapter"><a href="#id2749934">2. Design</a></span></dt><dd><dl><dt><span class="section"><a href="#id2759790">Overview</a></span></dt><dt><span class="section"><a href="#id2737277">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2763689">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2744686">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2754969">Nose Cone Electronics Bay</a></span></dt><dt><span class="section"><a href="#id2733689">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2763384">Avionics</a></span></dt><dt><span class="section"><a href="#id2740504">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2748086">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2767164">Recovery System</a></span></dt></dl></dd></dl></dd><dt><span class="chapter"><a href="#id2768933">3. Construction Details</a></span></dt><dd><dl><dt><span class="section"><a href="#id2749141">Airframe</a></span></dt><dt><span class="section"><a href="#id2754017">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2771414">Avionics Bay</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2745741">4. Recovery Systems Package</a></span></dt><dd><dl><dt><span class="section"><a href="#id2740673">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2752914">Recovery Initiation Control Components</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2748101">5. Checklists </a></span></dt><dt><span class="chapter"><a href="#id2750187">6. Flight Summary</a></span></dt><dt><span class="chapter"><a href="#id2764884">7. Analysis and Conclusions</a></span></dt></dl></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2744045"></a>Chapter 1. Introduction</h2></div></div></div><p>
- This is a rocket I'm building for my second attempt at a NAR Level 3
- certification flight. It's basically a Polecat Aerospace Goblin 10 kit
- augmented with an additional electronics bay in the nose cone, some
- structural reinforcement, and incorporating a few personal build
- preferences.
- </p><p>
- Preliminary analysis suggests that it should reach just under 7k feet
- on the Aerotech M1297W reload, and could break two miles on the
- Cesaroni M795W moon-burner. This means that a certification flight can
- be supported at Hudson Ranch with the standing 8k waiver, at the Tripoli
- Colorado site under their higher-altitude window, or at either of the
- NCR launch sites under their standing waivers.
- The smallest reasonable motor for this rocket would be a Cesaroni
- K445 or equivalent, which would yield an apogee of about 2300 feet.
- </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2749934"></a>Chapter 2. Design</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2759790">Overview</a></span></dt><dt><span class="section"><a href="#id2737277">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2763689">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2744686">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2754969">Nose Cone Electronics Bay</a></span></dt><dt><span class="section"><a href="#id2733689">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2763384">Avionics</a></span></dt><dt><span class="section"><a href="#id2740504">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2748086">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2767164">Recovery System</a></span></dt></dl></dd></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2759790"></a>Overview</h2></div></div></div><p>
- The Goblin 10 kit is a simple "four fins and a nose cone" rocket
- that is short and squat, with a 98mm motor mount.
- It supports dual-deploy by
- using the forward end of the long motor mount tube to hold the main.
- The primary electronics bay is between the forward two motor mount
- centering rings, accessed by a side hatch. An additional payload bay
- will be built inside the nose cone to carry experimental altimeters,
- a tracking beacon, and possibly a GPS position reporting system.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2737277"></a>Rocksim File</h2></div></div></div>
- This is the current working design in Rocksim format:
- <a class="ulink" href="Polecat_Goblin_10.rkt" target="_top"> Polecat_Goblin_10.rkt </a></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2763689"></a>Drawing from Rocksim</h2></div></div></div><span class="inlinemediaobject"><img src="Polecat_Goblin_10.jpg" height="450"></span></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2744686"></a>Motor Retention</h2></div></div></div><p>
- I will include 8-24 T-nuts in the aft centering ring spaced to allow
- the use of an Aeropack 98mm retainer and associated 75mm adapter.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2754969"></a>Nose Cone Electronics Bay</h2></div></div></div><p>
- Instead of using the supplied nose cone bulkhead, I intend to cut a
- custom one that would support installing a length of 98mm motor mount
- from the tip of the nose to the bulkhead. With a plate cut to cover
- the aft end of the airframe tube, this would form an electronics bay
- capable of holding a beacon transmitter, GPS system, or other custom
- electronics.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2733689"></a>Electronics</h2></div></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2763384"></a>Avionics</h3></div></div></div><p>
- The recovery system will feature dual redundant barometric altimeters
- in the main avionics bay between the two forward motor mount
- centering rings.
- </p><p>
- A PerfectFlite MAWD will be flown as the primary altimeter and to
- record the flight altitude profile.
- A MissileWorks Mini-RRC2 will fly as backup altimeter and to
- directly capture max velocity.
- </p><p>
- Each altimeter will have a separate battery and rotary power switch.
- A third rotary switch will be used as a SAFE/ARM switch configured
- to interrupt connectivity to all ejection charges in accordance with
- NAR certification requirements.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2740504"></a>Stability Evaluation</h3></div></div></div><p>
- The Goblin 10 kit designers indicate
- that the rocket is unconditionally stable with all motors that fit
- the motor mount geometry. Since we're adding mass at both ends, by
- putting a payload in the nose cone and by glassing the fins, the
- overall stability of the design should be retained, but simulation
- to confirm that seems prudent.
- </p><p>
- Thorough analysis using
- <a class="ulink" href="http://www.apogeerockets.com/rocksim.asp" target="_top">
- RockSim
- </a>
- with various motors ranging from the Cesaroni K445 through the
- Aerotech M1939W always shows the stability as marginal.
- This is typical of short fat rockets that don't meet normal length
- to airframe diameter ratio expectations.
- Given this, I take the fact that RockSim shows the stability as
- marginal instead of unstable as strong evidence that the rocket
- will in fact be stable in flight.
- I also note that the simulated margin of stability
- in my as-built configuration is fairly close to the margin of
- stability of the as-designed model.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2748086"></a>Expected Performance</h3></div></div></div><p>
- The Aerotech M1297W reload should carry this vehicle to just under
- 7000 feet AGL from Colorado Front Range launch sites. It
- should reach just over 2 miles on a Cesaroni M795 moon burner
- or equivalent.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2767164"></a>Recovery System</h3></div></div></div><p>
- The recovery system will use dual redundant barometric altimeters
- firing 4F black powder charges using commercial e-matches.
- At apogee, a drogue chute will deploy with separation of the nose
- cone. A Giant Leap TAC-1 36 inch chute already in hand will serve
- as the drogue.
- At a preset altitude, a main chute will be deployed from the forward
- end of the motor mount tube to achieve recovery of the bulk of the
- rocket at approximately 20 ft/sec.
- </p><p>
- I intend to sew the main parachute from scratch with my wife's help
- using a design documented by
- <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
- Team Vatsaas
- </a>
- using 1.9oz rip-stop nylon and 550 lb parachute cord. The anticipated
- build weight implies that a 10 foot parachute would be appropriately
- sized.
- </p><p>
- The recovery system attachment points will all use 1/4 inch u-bolts
- with nuts, washers, and backing plates through bulkheads.
- </p></div></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2768933"></a>Chapter 3. Construction Details</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2749141">Airframe</a></span></dt><dt><span class="section"><a href="#id2754017">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2771414">Avionics Bay</a></span></dt></dl></div><p>
- I have collected all of my
- <a class="ulink" href="http://gallery.gag.com/rockets/goblin10" target="_top">
- build photos
- </a>
- in one place, they may show better than I can explain how various
- aspects of the Goblin went together.
- </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2749141"></a>Airframe</h2></div></div></div><p>
- The airframe tubing provided in the Polecat kit is thick cardboard tube
- with a thin exterior fiberglass wrap. To increase airframe strength,
- and particularly to prevent zippers, additional reinforcement seemed
- warranted.
- </p><p>
- The inner layer of paper was removed from the front 9" or
- so of the tube. The tube was soaked with West Systems epoxy diluted
- with about 20% by volume with acetone, and then a carbon fiber wrap was
- applied to the interior front of the tube and held in place during
- curing by an inflatable child's bounce toy inside a plastic garbage
- bag. The result is a substantially strengthened tube, with carbon
- fiber lining from the leading edge back past the first centering ring.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2754017"></a>Nose Cone</h2></div></div></div><p>
- The provided nose cone bulkhead was replaced by a custom centering
- ring cut from 3/8 inch birch plywood. The ring's outer diameter was
- adjusted put place the ring approximately an inch forward of the end
- of the motor mount tube, and the inner diameter was cut to fit Giant
- Leap 98mm phenolic airframe tubing. A length of such tubing was cut
- to fit inside the nose cone and extend back to flush with the trailing
- edge of the ring. The centering ring was drilled and fitted with two
- u-bolts for recovery system attachment and four 6-32 T-nuts to hold
- a payload mounting plate in place over the aft end of the 98mm tube.
- </p><p>
- The airframe tubing was glued into the tip of the nose cone with West
- Systems epoxy using both milled glass and microlite filler to thicken
- the mix. The centering ring was then epoxied in place using a similar
- mix around the outer edge to form a heavy fillet and 5-minute epoxy to
- the piece of airframe tubing. After the epoxies cured, a rotary tool
- was used to cut the airframe tubing off flush with the aft surface of
- the centering ring.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2771414"></a>Avionics Bay</h2></div></div></div><p>
- The avionics bay walls were installed approximately 90 degrees apart
- prior to installation of the motor mount assembly in the airframe.
- The airframe wall was marked for a 3.5 x 6.5" access hatch centered
- over the bay 90 degrees from the rail button line. This allows
- sufficient room to install the switches on one side of the hatch yet
- still inside the bay, and to place the static vent on the other side
- of the hatch so that there will be minimal effect from air disturbed
- by movement over the hatch cover edges.
- </p><p>
- Rails were fabricated from 3/8" birch plywood and 6-32 blind nuts to
- allow for a removable avionics sled, rectangular, with 4 screws to
- hold the sled in place.
- A suitably sized avionics sled should be possible to install and remove
- through the avionics bay hatch allowing for possible future experiments
- with alternative avionics.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2745741"></a>Chapter 4. Recovery Systems Package</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2740673">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2752914">Recovery Initiation Control Components</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2740673"></a>Recovery System Description</h2></div></div></div><p>
- This rocket uses dual deployment.
- </p><p>
- The apogee event separates the nose cone from the
- airframe. The nose cone is attached to the airframe with a length
- of heavy-duty tubular nylon shock cord. A drogue chute protected
- during ejection by a kevlar blanket is attached to the shock cord
- close to the nose cone end.
- </p><p>
- The main is a 10 foot chute sewn from the design documented by
- <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
- Team Vatsaas.
- </a>
- It is held in place prior to ejection by a layer of paper taped over
- the front of the motor mount tube. At ejection, a piston pushes the
- chute forward through the paper and ejects it from the rocket.
- This chute is attached to the airframe through an additional length of
- heavy-duty tubular nylon shock cord.
- </p><p>
- Depending on the results of ground testing, the main chute may be
- packed in a Giant Leap kevlar deployment bag attached at the main
- chute apex, with a smaller drogue chute deployed to pull off the bag
- and cleanly deploy the main. The primary motivation for this is to
- prevent the main chute shrouds from tangling during ejection.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2752914"></a>Recovery Initiation Control Components</h2></div></div></div><p>
- The main avionics bay between the forward two centering rings is
- populated with two commercial altimeters, a PerfectFlite MAWD
- and a Missile Works miniRRC2.
- Each is powered by a dedicated 9V alkaline battery, and has a
- dedicated on/off power switch mounted for access from outside the
- rocket. Additionally, a single safe/arm switch with two poles is used
- to interrupt the return circuits from the igniters to each altimeter.
- See the attached schematic of the avionics bay contents for more
- details.
- </p><p>
- Details of ejection charge design goes here.
- </p><p>
- The
- <a class="ulink" href="http://www.info-central.org/recovery_powder.shtml" target="_top">
- Info Central Black Powder Sizing
- </a>
- page is the most authoritative site I've found on this topic.
- The formula they suggest is diameter in inches squared times
- length in inches times a coefficient in grams of black powder.
- For the main charge, which will be in the 98mm motor mount tube, a
- pressure of 15psi is appropriate giving a coefficient of 0.006.
- For the drogue charge, which will be in the main airframe, a
- pressure of 5psi is more appropriate, leading to a coefficient
- of 0.002.
- </p><p>
- The drogue bay is 10 inches ID at the widest point, but contains
- the protrusion of the main bay and a decreasing radius in the
- nose cone. Thus some fudging on the length is appropriate, and
- we will use 18 inches. That works out to 3.6 grams of BP. This
- rocket will not fly high enough for there to be a significant
- effect on BP burn characteristics, so no special compensation
- should be required.
- </p><p>
- The main bay is 3.9 inches ID and perhaps as much as 24 inches long
- depending on which motor is selected.
- That works out to 2.2 grams of BP.
- </p><p>
- Ground testing yielded 3.5 grams for the apogee charge and 1.5 grams
- for the main.
- Backup charges will contain additional BP in accordance
- with the "blow it off or blow it up" philosophy.
- </p><p>
- With a 10 foot Team Vatsaas design parachute and our
- anticipated build weight, the descent rate under main
- should be just over 20 feet per second.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2748101"></a>Chapter 5. Checklists </h2></div></div></div><div class="orderedlist"><ol type="1"><li>
- Planning
- <div class="orderedlist"><ol type="1"><li>
- Pick a club launch with suitable waiver and facilities to
- support flight.
- </li><li>
- Confirm L3CC member(s) available to attend selected launch.
- </li><li>
- Confirm that required loaner motor hardware will be available at launch.
- </li><li>
- Notify launch sponsor (club president) of intended flight.
- </li><li>
- Notify interested friends of intended flight.
- </li><li>
- Perform final pre-flight simulation with as-built masses, etc.
- </li><li>
- Gather consummables and tools required to support flight
- <div class="orderedlist"><ol type="1"><li>
- fresh 9V batteries
- </li><li>
- black powder
- </li><li>
- e-matches
- </li><li>
- motor retainer and adapter parts
- </li><li>
- small nylon wire ties
- </li><li>
- cellulose wadding material
- </li><li>
- masking tape
- </li><li>
- screwdriver for phillips-head avionics bay screws
- </li><li>
- small straight-blade screwdriver for power switches
- </li><li>
- motor reload kit (or arrangements to procure at launch)
- </li><li>
- high temperature grease
- </li><li>
- long small diameter dowels for igniter insertion
- </li></ol></div></li></ol></div></li><li>
- Before Leaving Home
- <div class="orderedlist"><ol type="1"><li>
- program altimeters for suitable mach delay and recovery deployment
- <div class="itemizedlist"><ul type="disc"><li>
- MAWD
- <div class="itemizedlist"><ul type="circle"><li>
- no mach delay
- </li><li>
- 1300 foot main deploy
- </li></ul></div></li><li>
-
- miniRRC2
- <div class="itemizedlist"><ul type="circle"><li>
- no mach delay
- </li><li>
- 1000 foot main deploy
- </li><li>
- 2 seconds apogee delay
- </li><li>
- no main delay
- </li><li>
- dual deploy
- </li><li>
- ops mode 16 (default)
- </li></ul></div></li></ul></div></li><li>
- assemble all recovery system components and ensure everything fits
- </li><li>
- confirm wiring and operation of altimeter power and safe/arm
- switches
- </li><li>
- Ground test recovery system to confirm suitable black powder
- charge sizing
- </li></ol></div></li><li>
- Pre-Flight
- <div class="orderedlist"><ol type="1"><li>
- confirm payload batteries in good condition, bay loaded,
- power switch works
- </li><li>
- confirm reception of signals from transmitter(s)
- </li><li>
- install fresh 9V batteries for altimeters on avionics bay sled
- </li><li>
- inspect altimeters and associated avionics bay wiring for
- visible faults
- </li><li>
- close up avionics bay
- </li><li>
- build and install BP charges
- <div class="orderedlist"><ol type="1"><li>
- Drogue Primary Charge - 3.5 grams 4F BP
- </li><li>
- Drogue Backup Charge - 4.0 grams 4F BP
- </li><li>
- Main Primary Charge - 1.5 grams 4F BP
- </li><li>
- Main Backup Charge - 2.0 grams 4F BP
- </li></ol></div></li><li>
- fold main chute, connect recovery harness to piston and airframe,
- install in MMT and tape paper over the front end
- </li><li>
- fold drogue chute into a kevlar pad, connect recovery harness to
- nose cone and airframe, install in airframe
- </li><li>
- power up payload using switch on base plate in nose cone, then
- install nose cone, using masking tape to adjust fit as required
- </li><li>
- safely power up altimeters, operate safe/arm switch,
- and confirm e-match continuity
- </li><li>
- safe and power-down the altimeters
- </li><li>
- load motor per manufacturer instructions
- </li><li>
- install motor in motor mount
- </li><li>
- install motor retention
- </li><li>
- prepare igniter using e-matches, 1/8 inch dowel
- </li><li>
- confirm all screws in place, avionics off and safe
- </li><li>
- fill out a launch card
- </li><li>
- notify RSO/LCO of readiness for inspection and launch, obtain
- a rail assignment and permission to move rocket to launch pad for
- final prep
- </li><li>
- coordinate readiness with support team members, photographers,
- observers
- </li></ol></div></li><li>
- Final Prep
- <div class="orderedlist"><ol type="1"><li>
- move rocket to launch area
- </li><li>
- clean and lubricate launch rail if necessary
- </li><li>
- confirm reception of signals from payload transmitter(s)
- </li><li>
- mount rocket on launch rail, rotate to vertical
- </li><li>
- power up primary altimeter, confirm expected beep pattern
- </li><li>
- power up backup altimeter, confirm expected beep pattern
- </li><li>
- arm ejection charges
- </li><li>
- confirm altimeters both giving expected beep patterns for
- igniter continuity
- </li><li>
- install igniter and connect to launch control system
- </li><li>
- capture GPS waypoint for rail location
- </li><li>
- smile for the cameras, make sure we have enough "foil Murphy!"
- shots taken
- </li><li>
- retreat to safe area behind LCO
- </li><li>
- confirm continued reception of transmitter signal(s) from
- payload bay
- </li><li>
- confirm photographers and observers are ready and know what to
- expect
- </li><li>
- make sure binoculars and backpack with water and recovery tools
- are at hand
- </li><li>
- tell RSO and LCO we're ready to launch
- </li><li>
- try to relax and enjoy watching the flight!
- </li></ol></div></li><li>
- Recovery
- <div class="orderedlist"><ol type="1"><li>
- track rocket to landing site
- </li><li>
- capture GPS waypoint of landing site, take lots of photos
- </li><li>
- note any damage
- </li><li>
- gather up and roughly re-pack recovery system for return to
- flight line
- </li><li>
- bring the rocket to observers for post-flight inspection
- </li></ol></div></li></ol></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2750187"></a>Chapter 6. Flight Summary</h2></div></div></div><p>
- A successful level 3 certification flight occurred on 15 November 2008
- at the SCORE Hudson Ranch launch facility. The motor was an Aerotech
- M1297W provided by Tim Thomas of Giant Leap Motors, the igniter was
- assembled by James Russell using his special thermite mixture, and
- numerious SCORE, COSROCS, and NCR members were present to assist with
- the launch! Great weather for November... mostly clear and sunny,
- light winds, dry ground, temps above freezing.
- </p><p>
- The motor came up to pressure very quickly and the rocket leapt off
- the pad, climbing smoothly under power and then doing about two slow
- rolls during the coast phase. Deployment of the nose cone and drogue
- occurred as planned when the primary apogee charge fired.
- Unfortunately, the main deployed around the time the backup apogee
- charge fired, so the descent was under main from apogee. Fortunately,
- the winds were low enough and the descent rate high enough that the
- rocket touched down without damage within the waiver area for a
- successful certification!
- </p><p>
- The rocket weighed 25.2 pounds prepared for launch without the motor.
- The motor weighed about 10.25 pounds, which included about 6 pounds
- of propellant. Thus the descent mass under chute was just over 29
- pounds.
- The miniRRC2 altimeter reported 5949 feet apogee, 980 feet per second
- max velocity, and 19 seconds to apogee. The MAWD reported 5953 feet
- apogee.
- </p><div class="itemizedlist"><ul type="disc"><li><a class="ulink" href="http://picasaweb.google.com/jamesr2/StealeyMemorialLaunchSiteHudsonRanch" target="_top">
- Photos of the launch taken by James Russell
- </a></li><li><a class="ulink" href="http://cosrocs.org/all%20other%20videos/2008videos/11-15hudson/bdale_L3.mov" target="_top">
- Video of the launch taken by Jeff Lane
- </a></li><li><a class="ulink" href="http://www.youtube.com/watch?v=xaJnl89wfWU" target="_top">
- Video of the launch taken by Jason Unwin
- </a></li></ul></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2764884"></a>Chapter 7. Analysis and Conclusions</h2></div></div></div><p>
- The ascent was straighter than expected... very smooth during
- the motor burn, then a couple slow rolls during coast. The two
- altimeters agreed within 4 feet on the apogee. The max
- velocity recorded is a little higher than predicted by simulation,
- but the accuracy of that measurement is likely limited since it is
- based on pressure data.
- </p><p>
- I was able to watch the apogee events through binoculars, and could
- clearly see the main deploy as the backup apogee charge fired. I saw
- some evidence of tearing of the paper taped over the motor mount to
- retain the main chute during ground testing, so assume this was the
- root cause of the early deployment. When the backup apogee charge
- fired, the shock cord was not yet in tension, and thus the charge
- probably kicked the airframe backwards hard enough to allow the main
- chute to slide out through the torn paper and deploy. The best fix
- for this might be
- to fabricate a second piston to use as a cap and retain it with two
- shear pins. This would be much less likely to prematurely deploy than
- the current taped paper approach.
- </p><p>
- The most significant variance from expectation was the descent rate.
- The spreadsheet provided by the Team Vatsaas folks for their design
- suggested we'd see around 21 feet per second. Analysis of the flight
- profile from the MAWD shows that our actual descent rate was about
- 32 feet per second. There are three possible sources of error to
- consider.
- </p><div class="orderedlist"><ol type="1"><li>
- The first is descent mass. Pre-flight calculations used
- 25 pounds.
- The actual flight weight was 25.2 pounds plus the burn-out
- weight of the M1297W, which should be about 4.5 pounds.
- That yields 29.5 pounds total. All pre-flight calculations
- were done using 25 lbs, with the thought that the motor mass
- might cancel out against the drag provided by the drogue.
- In flight, it appeared the drogue supported the nose and the
- main supported the fin can with very little interaction between
- the two.
- </li><li>
- Second, the dimensions given by Team Vatsaas' spreadsheet
- for the pattern grid seem small. For a 10 foot chute, they
- suggest a grid size of 5 inches, which looks more like an 8.5
- foot finished chute size to me.
- </li><li>
- Finally, the Cd in the spreadsheet is 1.5, which may be overly
- optimistic.
- </li></ol></div><p>
- My calculations show that if we assume a chute size of 8.5 feet and
- a Cd closer to 1, we can get to a descent rate of 32 feet per second.
- </p><p>
- So, overall, this was a successful flight, but with three things to
- change before we fly the airframe again...
- </p><div class="orderedlist"><ol type="1"><li>
- the main chute may be too small
- </li><li>
- switch to a piston to cap the main chute bay
- </li><li>
- beef up the battery retention on the avionics sled
- </li></ol></div><p>
- </p></div></div></body></html>
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-<MaxHorzAcceleration>0.240162</MaxHorzAcceleration>
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-<LaunchThermalHeight>2000.</LaunchThermalHeight>
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-<FinCantUncertainty>0.</FinCantUncertainty>
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-<LaunchGuideElevationUncertainty>0.</LaunchGuideElevationUncertainty>
-<IgnitionUncertainty>0.</IgnitionUncertainty>
-<CATOUncertainty>0.</CATOUncertainty>
-<DeploymentUncertainty>0.</DeploymentUncertainty>
-<RecoveryDeviceUncertainty>0.</RecoveryDeviceUncertainty>
-<SimulationName>[J330-None] </SimulationName>
-<VelocityAtLaunchGuideEnd>16.8513</VelocityAtLaunchGuideEnd>
-<WindStartAltitude>0.</WindStartAltitude>
-<TimeToWindShear>0.</TimeToWindShear>
-<TimeToFreeFlight>0.31375</TimeToFreeFlight>
-<TimeToMaxVelocity>2.06875</TimeToMaxVelocity>
-<TimeToMaxAcceleration>0.05</TimeToMaxAcceleration>
-<Nsims>10</Nsims>
-<CalcResolution>1</CalcResolution>
-<SamplesPerSecond>800.</SamplesPerSecond>
-<SimulationType>0</SimulationType>
-<LocationDataServerName>Earth</LocationDataServerName>
-<LocationDataServerDisplayName>Standard earth condistions.</LocationDataServerDisplayName>
-<ExecutionTime>2.163</ExecutionTime>
-<RangeAtLanding>-102.858</RangeAtLanding>
-<DirectionAtLanding>0.</DirectionAtLanding>
-<VelocityAtLanding>92.8518</VelocityAtLanding>
-<XVelcoityAtLanding>-5.21285</XVelcoityAtLanding>
-<YVelocityAtLanding>-92.7053</YVelocityAtLanding>
-<ZVelocityAtLanding>0.</ZVelocityAtLanding>
-<StageSeparationTime>0,0,0,0,0</StageSeparationTime>
-<StageEjectTime>-1,-1,-1,-1,-1</StageEjectTime>
-<TimeToDeployment>0,0,0,0,0</TimeToDeployment>
-<DeploymentType>32,32,32,32,32</DeploymentType>
-<SamplesPerSecondDescent>1.</SamplesPerSecondDescent>
-<CalculationFlags>1</CalculationFlags>
-<Mass0>6.552</Mass0>
-<CG0>1.7289</CG0>
-<LaterialMOI0>4.15113</LaterialMOI0>
-<RadialMOI0>0.0152822</RadialMOI0>
-<GUID>{4a48823c-7fc2-48b1-b2a3-30db719aa598}</GUID>
-<Booster1Staging>
-<SimulationEvent>
-<PartSerialNo>0</PartSerialNo>
-<Type>0</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>0</HasDeployed>
-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
-<DeployedAt_Velocity>0.</DeployedAt_Velocity>
-<DeployedAt_Range>0.</DeployedAt_Range>
-<DeployedAt_Time>0.</DeployedAt_Time>
-<DeviceID>-1</DeviceID>
-<TestType>0,0,0</TestType>
-<TestCondition>0,0,0</TestCondition>
-<TestValueAltitude>0,0,0</TestValueAltitude>
-<TestValueDegrees>0,0,0</TestValueDegrees>
-<TestValuePressure>0,0,0</TestValuePressure>
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-<Booster2Staging>
-<SimulationEvent>
-<PartSerialNo>0</PartSerialNo>
-<Type>0</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>0</HasDeployed>
-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
-<DeployedAt_Velocity>0.</DeployedAt_Velocity>
-<DeployedAt_Range>0.</DeployedAt_Range>
-<DeployedAt_Time>0.</DeployedAt_Time>
-<DeviceID>-1</DeviceID>
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-<TestValueTime>0,0,0</TestValueTime>
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-</Booster2Staging>
-<SimulationEvents>
-<SimulationEvent>
-<PartSerialNo>19</PartSerialNo>
-<Type>1</Type>
-<DeployAltitude>0.</DeployAltitude>
-<DeplyTime>0.</DeplyTime>
-<HasDeployed>0</HasDeployed>
-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
-<DeployedAt_Velocity>0.</DeployedAt_Velocity>
-<DeployedAt_Range>0.</DeployedAt_Range>
-<DeployedAt_Time>0.</DeployedAt_Time>
-<DeviceID>-1</DeviceID>
-<TestType>28,28,28</TestType>
-<TestCondition>0,0,0</TestCondition>
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-<TestValueDegrees>0,0,0</TestValueDegrees>
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-<SimulationEvent>
-<PartSerialNo>18</PartSerialNo>
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-<DeployedAt_Altitude>0.</DeployedAt_Altitude>
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-<SimulationEvent>
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-</RockSimDocument>
+++ /dev/null
-<html><head><meta http-equiv="Content-Type" content="text/html; charset=ISO-8859-1"><title>YikStik</title><meta name="generator" content="DocBook XSL Stylesheets V1.73.2"></head><body bgcolor="white" text="black" link="#0000FF" vlink="#840084" alink="#0000FF"><div class="book" lang="en"><div class="titlepage"><div><div><h1 class="title"><a name="id2322390"></a>YikStik</h1></div><div><h2 class="subtitle">A NAR L3 Certification Rocket</h2></div><div><div class="author"><h3 class="author"><span class="firstname">Bdale</span> <span class="surname">Garbee</span></h3></div></div><div><p class="copyright">Copyright © 2008 Bdale Garbee</p></div><div><div class="legalnotice"><a name="id2577753"></a><p>
- This document is released under the terms of the
- <a class="ulink" href="http://creativecommons.org/licenses/by-sa/3.0/" target="_top">
- Creative Commons ShareAlike 3.0
- </a>
- license.
- </p></div></div><div><div class="revhistory"><table border="1" width="100%" summary="Revision history"><tr><th align="left" valign="top" colspan="2"><b>Revision History</b></th></tr><tr><td align="left">Revision 1.2</td><td align="left">12 January 2009</td></tr><tr><td align="left" colspan="2">
- Document firmware bug in miniRRC2 and possible impact on flight.
- </td></tr><tr><td align="left">Revision 1.1</td><td align="left">5 December 2008</td></tr><tr><td align="left" colspan="2">
- Remove embedded images in favor of references to gallery.gag.com
- </td></tr><tr><td align="left">Revision 1.0</td><td align="left">28 October 2008</td></tr><tr><td align="left" colspan="2">
- Recording results of first, and only, flight attempt.
- </td></tr><tr><td align="left">Revision 0.5</td><td align="left">27 September 2008</td></tr><tr><td align="left" colspan="2">
- Building checklists
- </td></tr><tr><td align="left">Revision 0.4</td><td align="left">17 September 2008</td></tr><tr><td align="left" colspan="2">
- Documenting the build process as it happens
- </td></tr><tr><td align="left">Revision 0.3</td><td align="left">29 March 2008</td></tr><tr><td align="left" colspan="2">
- Incorporate ideas from James Russell during initial L3CC review
- </td></tr><tr><td align="left">Revision 0.2</td><td align="left">27 March 2008</td></tr><tr><td align="left" colspan="2">Cleaned up for initial review</td></tr><tr><td align="left">Revision 0.1</td><td align="left">16 March 2008</td></tr><tr><td align="left" colspan="2">Initial content</td></tr></table></div></div></div><hr></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="chapter"><a href="#id2565537">1. Introduction</a></span></dt><dd><dl><dt><span class="section"><a href="#id2565574">Why "YikStik"?</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2557207">2. Design</a></span></dt><dd><dl><dt><span class="section"><a href="#id2557213">Overview</a></span></dt><dt><span class="section"><a href="#id2557231">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2557244">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2557261">Airframe Tubing</a></span></dt><dt><span class="section"><a href="#id2557277">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2557288">Fins</a></span></dt><dt><span class="section"><a href="#id2608670">Centering Rings and Bulkheads </a></span></dt><dt><span class="section"><a href="#id2597438">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2599532">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2612550">Avionics</a></span></dt><dt><span class="section"><a href="#id2589090">Payload</a></span></dt></dl></dd><dt><span class="section"><a href="#id2581651">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2581446">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2599074">Recovery System</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2592234">3. Construction Details</a></span></dt><dd><dl><dt><span class="section"><a href="#id2599259">Airframe and Couplers</a></span></dt><dt><span class="section"><a href="#id2596433">Fins</a></span></dt><dt><span class="section"><a href="#id2606804">Centering Rings and Bulkheads</a></span></dt><dt><span class="section"><a href="#id2588775">Assembling the Booster Section</a></span></dt><dt><span class="section"><a href="#id2584973">Avionics Bay</a></span></dt><dt><span class="section"><a href="#id2606384">Payload Bay</a></span></dt><dt><span class="section"><a href="#id2607348">Recovery System</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2600260">4. Recovery Systems Package</a></span></dt><dd><dl><dt><span class="section"><a href="#id2595964">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2609782">Recovery Initiation Control Components</a></span></dt></dl></dd><dt><span class="chapter"><a href="#id2585586">5. Stability Evaluation</a></span></dt><dt><span class="chapter"><a href="#id2606777">6. Expected Performance</a></span></dt><dt><span class="chapter"><a href="#id2611290">7. Checklists </a></span></dt><dt><span class="chapter"><a href="#id2610811">8. Flight Summary</a></span></dt><dt><span class="chapter"><a href="#id2607490">9. Analysis and Conclusions</a></span></dt></dl></div><p>
- Please note that I stopped adding photos to this document at some
- point. I have many more photos of the YikStik build, but haven't
- decided how best to present them yet... update coming someday!
- </p><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2565537"></a>Chapter 1. Introduction</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2565574">Why "YikStik"?</a></span></dt></dl></div><p>
- This is the rocket I'm designing for my NAR Level 3 certification flight.
- The general idea is to build a fairly cheap rocket capable of reliably
- flying this year's Aerotech level 3 special, which is an M1297W reload.
- I'd like to be able to fly the prototype of my own altimeter design, and
- to be able to fly it often on smaller / cheaper reloads at launch sites
- with modest waivers like Hudson Ranch.
- </p><p>
- I want to experiment with vacuum bagging carbon fiber reinforcements, and
- intend to use my CNC milling machine to cut all the centering rings, etc.
- The new Giant Leap "Dynawind" tubing feels like a good choice, and if we
- stick to the 4 inch version we can use a cheap plastic nosecone to keep
- the cost down.
- </p><p>
- Preliminary analysis suggests that a roughly 8 foot rocket made from 4 inch
- airframe with a 75mm mount and three fins should fly to something around
- 14k feet on the M1297W, could break three miles on the M1850W, and yet
- could safely fly on reloads as small as a J for economical fun. Those
- altitudes mean the certification flight will need to be at a site with a
- high-altitude waiver like the NCR north site.
- </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2565574"></a>Why "YikStik"?</h2></div></div></div><p>
- I've always thought the high-gloss red paint job on one of my son's rockets
- when out on a launch rod in the sun looks a lot like glistening wet
- lipstick.
- </p><p>
- Combine that with the fact that my wife who isn't fond of the stuff
- refers to lipstick as "yik stick"... and the rest should be obvious.
- </p><p>
- My planned paint scheme is a bright red nosecone, gold tube, and black fin
- can, which is the mental image I have of what lipstick applicators look
- like, most likely from a stick my mother or one of my grandmothers had
- when I was a child.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2557207"></a>Chapter 2. Design</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2557213">Overview</a></span></dt><dt><span class="section"><a href="#id2557231">Rocksim File</a></span></dt><dt><span class="section"><a href="#id2557244">Drawing from Rocksim</a></span></dt><dt><span class="section"><a href="#id2557261">Airframe Tubing</a></span></dt><dt><span class="section"><a href="#id2557277">Nose Cone</a></span></dt><dt><span class="section"><a href="#id2557288">Fins</a></span></dt><dt><span class="section"><a href="#id2608670">Centering Rings and Bulkheads </a></span></dt><dt><span class="section"><a href="#id2597438">Motor Retention</a></span></dt><dt><span class="section"><a href="#id2599532">Electronics</a></span></dt><dd><dl><dt><span class="section"><a href="#id2612550">Avionics</a></span></dt><dt><span class="section"><a href="#id2589090">Payload</a></span></dt></dl></dd><dt><span class="section"><a href="#id2581651">Stability Evaluation</a></span></dt><dt><span class="section"><a href="#id2581446">Expected Performance</a></span></dt><dt><span class="section"><a href="#id2599074">Recovery System</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557213"></a>Overview</h2></div></div></div><p>
- YikStik is a fairly simple "three fins and a nose cone" dual-deploy
- rocket using a 75mm motor mount, 4 inch glass-wrapped phenolic airframe
- with zipperless fin can, plastic nose cone, plywood fins,
- and lots of glass and carbon fiber reinforcing.
- The primary electronics bay will be designed to
- hold two altimeters, and a distinct payload bay may carry an
- experimental altimeter, GPS receiver, and downlink transmitter.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557231"></a>Rocksim File</h2></div></div></div>
- This is the current working design in Rocksim format:
- <a class="ulink" href="YikStik.rkt" target="_top"> YikStik.rkt </a></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557244"></a>Drawing from Rocksim</h2></div></div></div><span class="inlinemediaobject"><img src="YikStik.jpg"></span></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557261"></a>Airframe Tubing</h2></div></div></div><p>
- I intend to cut the airframe components from two 48 inch lengths of
- 98mm Giant Leap Dynawind tubing. The 30 inch main bay and 18 inch drogue
- bay will be cut from one length, while the 33 inches of fin can, 2 inches
- of electronics bay, and 8 inches of payload bay will be cut from the
- second.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557277"></a>Nose Cone</h2></div></div></div><p>
- I intend to use a Giant Leap "Pinnacle" 3.9 inch nose cone.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2557288"></a>Fins</h2></div></div></div><p>
- The fins are designed from scratch, and I intend to build them up from
- two layers of 1/8 inch birch plywood, three layers of carbon fiber, and
- two layers of 6 oz glass. The stack will be glass, carbon fiber,
- plywood, carbon fiber, plywood, carbon fiber, glass. The edges of the
- plywood will be routed to give a modified airfoil shape to the finished
- fins. The stack will be laminated using West Systems epoxy products
- and vacuum bagged.
- The shape is a compromise between mass, surviving Mach-transition stress,
- optimal stability margin, and avoiding damage during handling and on
- contact with the ground during recovery.
- </p><p>
- The fins will be locked in to milled slots in two of the centering rings,
- and will be epoxied to the motor mount with glass reinforcing tape.
- The airframe will be slotted to allow the completed motor mount / fin
- assembly to be inserted from the rear, with fillets of epoxy applied
- inside and outside the airframe after insertion.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2608670"></a>Centering Rings and Bulkheads </h2></div></div></div><p>
- All centering rings and bulkheads will be custom machined from 3/8 inch
- birch plywood using my 3-axis CNC milling machine. Some rings will use
- laminated pairs of 3/4 inch total thickness to enable use of threaded
- inserts for 1/4-20 rail button screws or deep routing for fin alignment
- slots.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2597438"></a>Motor Retention</h2></div></div></div><p>
- I will embed three 8-24 T-nuts in the aft centering ring spaced to allow
- the use of home-made Kaplow clips to retain 75mm motors.
- The same holes may be used to attach custom motor mount adapters for
- smaller diameter motors.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599532"></a>Electronics</h2></div></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2612550"></a>Avionics</h3></div></div></div><p>
- The recovery system will feature dual redundant barometric altimeters
- in an electronics bay similar to the LOC design located between the
- drogue and main parachute bays.
- </p><p>
- A PerfectFlite MAWD will be flown as the primary altimeter and to
- record the flight altitude profile.
- A MissileWorks Mini-RRC2 will fly as backup altimeter and to
- directly capture max velocity.
- </p><p>
- Each altimeter will have a separate battery and power switch. A 4PDT
- slide switch will be used as a SAFE/ARM switch configured to interrupt
- connectivity to the ejection charges.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h3 class="title"><a name="id2589090"></a>Payload</h3></div></div></div><p>
- I hope to fly
- <a class="ulink" href="http://altusmetrum.org/" target="_top">
- my own altimeter design
- </a>
- as a payload in a short payload section just behind the nose cone.
- I have acquired the pieces to add a GPS receiver and RF downlink using
- ham radio frequencies to the payload to track the rocket's position
- during flight.
- This is not essential to fly,
- but could make recovery simpler and would just be fun to fly if I can
- get it all working and suitably ground and/or flight tested in time.
- </p></div></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2581651"></a>Stability Evaluation</h2></div></div></div><p>
- This design has been thoroughly analyzed using
- <a class="ulink" href="http://www.apogeerockets.com/rocksim.asp" target="_top">
- RockSim
- </a>
- with motors ranging from the
- Cesaroni J285 through the Aerotech M1850W and appears to be
- unconditionally stable across that range. The lowest margin is around
- 1.2 seen with the M1297W planned for my level 3 certification flight,
- albeit with many masses still only roughly estimated.
- </p><p>
- These simulations will be refined as the build proceeds and as-built
- stability verified before flight.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2581446"></a>Expected Performance</h2></div></div></div><p>
- The Aerotech M1297W reload should carry this vehicle without ballast
- to just over 14 thousand feet AGL. It should make over 16 thousand
- feet AGL on an M1850W, and should fly stably to roughly 2.5k feet AGL
- on a Cesaroni J285.
- </p><p>
- Hitting optimal mass on the largest motors may require
- ballast, depending on final build weight.
- My plan is to fly without ballast on the certification flight,
- trading some altitude for a slower and softer recovery.
- If the cert succeeds, then I might try an optimal mass
- flight sometime later on an M1850W or equivalent "bigger M"
- reload to join the "three mile club".
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599074"></a>Recovery System</h2></div></div></div><p>
- The recovery system will use dual redundant barometric altimeters firing
- black powder charges.
- At apogee, a drogue chute will deploy from just forward of the fin can,
- with size selected for an approximately 100 ft/sec descent rate.
- At a preset altitude, a main chute will be deployed to achieve recovery
- of the bulk of the rocket at under 20 ft/sec.
- The main chute will be packed in a deployment bag, configured as a
- "freebag" and pulled out of the airframe by a second drogue chute. This
- drogue will recover the nosecone and deployment bag separately from the
- remainder of the rocket which will recover under the main.
- </p><p>
- I intend to sew the parachutes from scratch using a design documented by
- <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
- Team Vatsaas
- </a>
- using 1.9oz rip-stop nylon and 550 lb parachute cord.
- If time runs short, equivalent chutes from SkyAngle,
- Rocketman, or Giant Leap could be substituted (at significantly higher
- cost).
- </p><p>
- The deployment bag will probably be purchased from Giant Leap. The
- recovery harness will probably use tubular kevlar, also from Giant Leap.
- </p><p>
- The recovery system attachment points will all use 1/4 inch u-bolts with
- nuts, washers, and backing plates through bulkheads except for the fin
- can. The fin can has insufficient room between the motor mount and
- the airframe inner wall for nuts and washers, so an alternative means of
- recovery system attachment is required. The fin can will be equipped
- with either a 3/16 inch stainless steel aircraft cable loop, or a loop
- of 1/2 inch tubular kevlar, bonded to the motor mount.
- If available, a screw-eye attached to the forward motor closure may be
- used instead of or in addition to this recovery attachment loop.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2592234"></a>Chapter 3. Construction Details</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2599259">Airframe and Couplers</a></span></dt><dt><span class="section"><a href="#id2596433">Fins</a></span></dt><dt><span class="section"><a href="#id2606804">Centering Rings and Bulkheads</a></span></dt><dt><span class="section"><a href="#id2588775">Assembling the Booster Section</a></span></dt><dt><span class="section"><a href="#id2584973">Avionics Bay</a></span></dt><dt><span class="section"><a href="#id2606384">Payload Bay</a></span></dt><dt><span class="section"><a href="#id2607348">Recovery System</a></span></dt></dl></div><p>
- I have collected all of my
- <a class="ulink" href="http://gallery.gag.com/rockets/yikstik" target="_top">
- build photos
- </a>
- in one place, they may show better than I can explain how various
- aspects of YikStik went together.
- </p><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2599259"></a>Airframe and Couplers</h2></div></div></div><p>
- The tubing for the airframe, couplers, and motor mount was all cut
- using a carefully aligned and adjusted power mitre saw, and the ends
- lightly sanded to remove rough spots.
- The main and drogue bays were cut from one 48 inch length of Giant
- Leap 98mm Dynawind tubing, the fin can, electronics bay, and payload
- bay were cut from the second. The three couplers for the fin can,
- electronics bay, and payload bay were cut from Giant Leap 98mm phenolic
- coupler stock. And the motor mount was cut from Giant Leap 75mm
- phenolic airframe stock.
- Note that the motor mount is the longest piece because of
- the zipperless design with full-length motor mount.
- </p><p>
- The airframe tubing selected includes a wrap of 10oz glass in epoxy
- over the base phenolic tubing (visible in some photos as a
- shine on the outside of the tubing),
- but the coupler stock is unreinforced.
- To ensure the couplers can handle the anticipated loading, I reinforced
- each with one layer of interior carbon fiber, using the "kitchen
- vacuum bagging" technique documented by
- <a class="ulink" href="http://www.jcrocket.com/kitchenbagging.shtml" target="_top">
- John Coker.
- </a>
- </p><p>
- This was my first hands-on experience working with carbon fiber. The
- end of the coupler nearest the unit during bagging experienced some
- crushing of the fibers right at the end. It doesn't matter for this
- project because each of the couplers will have at least one end fitted
- with a bulkhead or centering ring, but in the future I'll be tempted
- to cut the coupler stock a bit long before bagging and trim to length
- after reinforcing to get "perfect" ends. The technique worked
- marvelously otherwise, and the resulting couplers look and should work
- great!
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2596433"></a>Fins</h2></div></div></div><p>
- Six pieces of 1/8 inch birch plywood were stacked, edge-aligned on what
- would be the fin root edge, and clamped. The outline of the fin design
- was marked in pencil, and three 1/8 inch holes drilled through the
- stack inside the fins to allow using 4-40 screws and nuts to hold the
- blanks together while making the initial cuts, so that they would all be
- matched in size. The clamps were removed to avoid interference
- during cutting. The fin outline was then cut using a radial arm saw.
- </p><p>
- A router table with 1/8 inch
- roundover bit was then used to round over the outer edge, 3 blanks on
- one side and three on the other. This edge might have been left square,
- but I prefer the look and feel of rounding. The router table with a 1/2
- inch diameter straight cutting bit and a fin beveling jig was used
- to impart a 10-degree bevel on the leading and trailing edge of each fin
- blank, again 3 on one side and three on the other. The resulting 6
- blanks thus form 3 pairs of fin components with a modified
- airfoil shape.
- </p><p>
- The fin assembly started with a simple lamination of two layers of ply
- sandwiching a layer of carbon fiber. Each fin used "one pump" of West
- Systems epoxy and the stack was vacuum bagged using the Foodsaver with
- wide bagging material. To keep everything flat while the epoxy cured,
- the stack of fins was sandwiched between two unused extra shelves for
- a storage cabinet I had on hand
- (particle board covered in laminate, very
- flat and smooth, nearly inflexible at this loading), and stacked with
- about 75 lbs of loose barbell weights.
- </p><p>
- On one of the three fins, the plywood layers are out of alignment by
- 1-2mm in the longest axis. The other two are nearly perfect. Light
- sanding should allow me to match them before laminating the outer layers
- of carbon fiber and glass.
- </p><p>
- After the fins cured, they were bulk sanded with medium and fine
- sandpaper and an electric palm sander. Final sanding of the leading
- and trailing edges was done using 400 grit paper on a flat surface,
- holding the fin the way you'd sharpen a knife against a stone. The
- results seem good, all three fins match pretty closely.
- </p><p>
- A fin holding jig was cut from 1/8" hardboard using my rotary tool
- with a fiber cutoff wheel. The fin slots were made to be a snug fit.
- A small batch of epoxy was used to apply a bead to the root edge and
- tab at the leading edge, then the fins were installed against the
- motor mount and locked into place with the jig to cure. The centering
- ring that locks the aft edge of the fins was dry-fit during this
- operation to ensure proper alignment, but was not glued yet. It will
- go on after the airframe and internal fin filets are installed.
- </p><p>
- The fins were reinforced with fiberglass and epoxy. Masking tape was
- used to carefully delineate where the airframe ID will be, then 6oz
- glass 14.25" by 3.5" was epoxied fin-fin across the MMT. Strips of
- 8.6oz "boat tape" fiberglass were worked into the joints with more
- epoxy, and a sheet of plastic covered by ziplog bags of water were
- used to hold things in place during the initial curing. The three
- sides were done one at a time and allowed to cure before proceeding.
- The results look good, and in combination with internal and external
- airframe filets should yield a super-strong fin can.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2606804"></a>Centering Rings and Bulkheads</h2></div></div></div><p>
- Pairs of 3/8 inch birch plywood blanks were laminated using Titebond
- wood glue and clamped while curing to form 3/4 inch blanks for centering
- rings. From a strength perspective, 3/8 inch should suffice, but there
- are two reasons for going with thicker blanks in some places. The first
- is that the rail buttons chosen use 1/4-20 mounting screws, and threaded
- inserts in that size are nearly 3/8 inch outside diameter
- (and thus would
- tear up a ring only 3/8 inch thick on insertion). The second is that I
- like to mill slots in the centering rings on each end of the fins to
- "lock" the fins into position. Doubling the blanks used to cut those
- rings will allow me to cut 1/4 inch deep fin slots and still have a half
- inch of unmolested wood in the rings for strength.
- </p><p>
- The aft centering ring and the one just aft of the zipperless
- coupler section were edge-drilled for the installation of brass
- 1/4-20 threaded inserts to hold rail buttons. The inserts were
- locked in place with epoxy, then ground down until nothing protruded
- beyond the OD of the ring.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2588775"></a>Assembling the Booster Section</h2></div></div></div><p>
- The forward two centering rings were installed on the MMT using
- JB Weld high-temperature epoxy, and incorporating an aircraft cable
- loop for recovery system retention since there just wasn't room for
- u-bolts.
- </p><p>
- The ring at the leading edge of the fins was initially installed
- assuming the aft ring would be nearly flush with the rear of the MMT
- and equipped with Kaplow-clip style retainers, but before the fins
- were installed a Giant Leap Slimline Tailcone Retainer for 75mm motor
- in 98mm airframe became available thanks to Tim Thomas, and so this
- ring was cut out and replaced with another one inch farther forward
- to allow installation of the tailcone at the rear of the MMT. I
- really like the tailcone on my Vertical Assault kit, and think it'll
- work out to be a great addition for this rocket!
- </p><p>
- An alignment jig for the fins was carefully marked out and then cut
- from 1/8 inch hardboard using my rotary tool and abrasive cutoff wheel.
- The fins were then epoxied at the root and short leading edge to the
- motor mount tube and into the slots in the forward centering ring,
- and held rigidly aligned by the jig until the epoxy set. The fins
- were then masked at what would be the ID of the airframe tube, and
- reinforced with 6oz glass fin-fin across the motor mount tube between
- each fin pair, further reinforced with strips of 1 inch glass "boat
- tape" at each fin root joint.
- </p><p>
- The airframe tubing section was carefully marked for fin slots, which
- were then cut using my rotary tool with abrasive cutoff wheel. Epoxy
- was applied ahead of the center two rings as the frame was slid into
- place, and the frame left standing upright until the epoxy set to
- hopefully form ring-fin fillets on those two rings. The interior
- fin to airframe joints were reinforced one fin at a time using West
- Systems epoxy will milled glass as a filler. A long 3/8" dowel was
- used to place and smooth these interior filets. The aft centering ring
- was installed by pouring West Systems epoxy in the three fin-fin gaps,
- placing the ring, then standing the airframe up to allow the epoxy to
- flow over the forward surface of the ring and into the gaps between it,
- the motor mount, and the airframe tubing. After it set, the booster
- was placed nose-down, the airframe gaps behind the fins were taped,
- and more epoxy was applied to seal the aft of the ring to the tubes.
- Before this epoxy set, JB Weld was used to glue the tail cone retainer
- in place on the MMT.
- </p><p>
- The exterior fin to
- airframe joints were filleted using 5-minute epoxy thickened with
- baby powder and smoothed with the tip of a plastic spoon, which I
- learned about building the Vertical Assault kit. Gives great results,
- and allowed all 6 joints to be done in one session. The space
- above the top surface of the forward centering ring and between the
- motor mount and zipperless-design coupler tubing was filled with epoxy
- and milled glass. Minor gaps in the airframe behind each fin were
- filled with epoxy clay.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2584973"></a>Avionics Bay</h2></div></div></div><p>
- The avionics bay contains the two commercial altimeters used to
- record information about the flight and deploy the drogue and main
- recovery systems. It is constructed of a piece of Giant Leap 98mm
- coupler tubing reinforced with an interior wrap of vacuum-bagged
- carbon fiber, and a 2 inch length of Giant Leap 98mm DynaWind airframe
- tubing.
- </p><p>
- The bulkheads are custom-milled from 3/8 inch birch plywood
- milled so that about 3/16" fits inside the coupler and the remainder
- seals the end of the coupler and just fits inside the airframe. Each
- bulkhead has a u-bolt for attaching the recovery harnesses, and dual
- CPVC end caps as ejection charge holders with screw terminal blocks
- from Missile Works to attach the igniters. Two lengths of 1/4 inch
- all-thread with nuts and washers tie the bulkheads together, with
- wing-nuts used on one end to allow for easy disassembly.
- </p><p>
- A sled was fabricated to hold the altimeters and batteries. It
- consists of 1/8 inch birch ply laminated with 6oz fiberglass on each
- side, epoxied to cardboard tubes taken from the packaging for Aerotech
- igniters that slide over the all-thread, further reinforced with nylon
- ties at each end. The tubes are staggered one on either side so that
- the sled goes right up the center of the airframe tubing.
- </p><p>
- Two "centering rings" containing three each 6-32 threaded inserts are
- epoxied inside the bay to provide hard points for attaching the
- airframe tubes for the drogue and main recovery bays. The inside
- diameter of these rings is notched for the avionics sled, and thus
- these rings also provide physical support for the sled.
- </p><p>
- Three rotary switches from Missile Works are installed through the
- short airframe tubing section, drilled such that they end up
- essentially flush with the outside of the airframe, clamp the coupler
- tubing, and project inside the bay. Two are wired as SPST switches
- for power to the two altimeters, the third is wired as a DPST switch
- that open-circuits the igniters for the required "safe/arm" function
- called for in the NAR L3 certification requirements.
- </p><p>
- The wiring of the avionics bay is documented in the attached
- schematic diagram. Connectors were used to allow each bulkhead and
- the switches in the housing to be quickly detached from the sled.
- The connectors are 9-pin D shells for the switch wiring, and 4-pin
- Molex connectors like those used on older PC hard drive power cables
- for the bulkheads. To allow use of a single switch pole for the
- safe/arm function for each altimeter, the two igniters attached to
- each altimeter are safed by interrupting the common return lines as
- shown in the schematic.
- </p><p>
- Sizing the static port for the avionics bay was done by applying the
- formulas suggested by PerfectFlite and Missile Works for their
- respective altimeter products, then comparing the results with each
- other and with information found on the web. I've personally had
- better luck with single ports than with multiple holes, perhaps because
- I've been working with relatively small rockets. Regardless, I'm
- sticking with what I know and will use a single static port hole here.
- </p><p>
- The measured dimensions
- of the avionics bay as constructed are 95mm ID and approximately 250mm
- between bulkheads. This works out to 108.73 cubic inches before
- accounting for the volume of the sled, electronics, and wiring and
- other components inside the bay. By the PerfectFlight formula, the
- static port should be 0.221 inches in diameter. By the Missile Works
- formula for a bay over 100 cubic inches the answer is 0.261 inches.
- The closest standard drill size, which happens to split the difference,
- is 0.250 inches. Easy enough!
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2606384"></a>Payload Bay</h2></div></div></div><p>
- The construction of the payload bay is very similar to the avionics
- bay, except that there is a hard-epoxied rear bulkhead, and only one
- screw ring to hard-mount the nose cone. The forward end of the
- payload bay is open to the open interior volume of the nose cone in
- anticipation of extending downlink antennas above the carbon fiber
- reinforcement in the coupler and into the nose cone, since carbon
- fiber is opaque to RF.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2607348"></a>Recovery System</h2></div></div></div><p>
- Pre-sewn 1/4 inch tubular kevlar harness sections were purchased
- from Giant Leap, along with a small kevlar deployment bag and two
- kevlar chute protectors.
- </p><p>
- For an apogee drogue, I plan to fly a Public Missiles 4 x 144 inch
- nylon streamer. It will be protected with one of the kevlar blankets
- and attached to one of the kevlar harness sections holding the booster
- to the avionics bay.
- </p><p>
- The main parachute will be sewn from 1.9 oz rip-stop nylon purchased
- from the
- <a class="ulink" href="http://www.milloutletfabric.com/" target="_top">
- Mill Outlet Fabric Shop
- </a>
- in Colorado Springs. Using the spreadsheet from
- <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
- Team Vatsaas
- </a>
- I calculate that we want an 8 foot chute to keep the airframe less
- nose cone and payload bay below 20 feet per second at touch-down.
- </p><p>
- To extract the main chute and recover the nose cone and payload bay,
- a 3 foot parachute from BSD Rocketry will be packed in a kevlar
- blanket ahead of the main chute deployment bag, attached by kevlar
- harness to the nose cone and payload bay assembly, and to the top of
- the deployment bag. This assembly will recover separately from the
- rest of the rocket.
- </p><p>
- The altimeters are programmed such that the MAWD fires its drogue
- charge at apogee and its main charge at 1100 feet. The miniRRC2
- is programmed to fire its drogue charge two seconds past apogee,
- and its main charge at 900 feet. Thus the MAWD is primary and the
- miniRRC2 is the backup. Since the M1297W has a burn time of about
- 5 seconds, mach inhibit is programmed on both altimeters to 8 seconds.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2600260"></a>Chapter 4. Recovery Systems Package</h2></div></div></div><div class="toc"><p><b>Table of Contents</b></p><dl><dt><span class="section"><a href="#id2595964">Recovery System Description</a></span></dt><dt><span class="section"><a href="#id2609782">Recovery Initiation Control Components</a></span></dt></dl></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2595964"></a>Recovery System Description</h2></div></div></div><p>
- This rocket uses dual deployment.
- </p><p>
- The apogee event separates the
- airframe between the zipperless-design booster section and the
- drogue bay. These two sections are linked by a Giant Leap 20 foot
- pre-sewn 1/4 inch tubular kevlar assembly, attached to which is a
- Public Missiles 4 x 144 inch red nylon streamer packed in a Giant Leap
- kevlar chute protection pad.
- </p><p>
- The main event separates the airframe between the forward payload bay
- and the main bay. Attached to the nose cone and payload bay assembly
- is a Giant Leap 15 foot pre-sewn 1/4 inch tubular kevlar assembly,
- attached "free bag" style to the top of a Giant Leap deployment bag
- containing the main chute. A 36 inch BSD Rocketry nylon parachute
- packed in a Giant Leap kevlar chute protection pad serves to pull the
- deployment bag off the main chute, after which it allows for safe
- recovery of the nose cone and payload assembly at just under 20 feet
- per second.
- </p><p>
- The 8 foot main chute is home-made from 1.9 oz rip-stop nylon using
- the design documented by
- <a class="ulink" href="http://www.vatsaas.org/rtv/systems/Parachutes/Chute.aspx" target="_top">
- Team Vatsaas.
- </a>
- It is attached to the remainder of the rocket using another Giant Leap
- pre-sewn 1/4 inch tubular kevlar assembly.
- </p><p>
- The anchor points are all 5/16 inch u-bolts, except for on the booster
- which is equipped with an embedded loop of 3/16 inch stainless aircraft
- cable. All connections are made with suitable quick-links.
- </p></div><div class="section" lang="en"><div class="titlepage"><div><div><h2 class="title" style="clear: both"><a name="id2609782"></a>Recovery Initiation Control Components</h2></div></div></div><p>
- The LOC-style avionics bay between the main and drogue bays is
- populated with two commercial altimeters, a PerfectFlite MAWD
- and a Missile Works miniRRC2.
- Each is powered by a dedicated 9V battery, and has a
- dedicated on/off power switch mounted for access from outside the
- rocket. Additionally, a single safe/arm switch with two poles is used
- to interrupt the return circuits from the igniters to each altimeter.
- See the attached schematic of the avionics bay contents for more
- details.
- </p><p>
- The bulkheads at each end of the avionics bay have two CPVC end caps
- for ejection charge holders, and two-terminal screw blocks for
- attachment of electric matches purchase from Giant Leap used to ignite
- Goex 4F black powder ejection charges. Each charge holder and terminal
- block pair is labelled as to main or backup since the charges will be
- different for each.
- </p><p>
- The
- <a class="ulink" href="http://www.info-central.org/recovery_powder.shtml" target="_top">
- Info Central Black Powder Sizing
- </a>
- page is the most authoritative site I've found on this topic.
- Each of the main and drogue bay interfaces will use 2 2-56 nylon screws
- as shear pins, each of which needs 35 pounds of force or so to shear.
- Designing for 15psi puts us between 150 and 200 pounds total force in
- a 4 inch airframe. The formula is thus 0.006 grams times diameter
- squared in inches times length in inches.
- </p><p>
- My drogue bay is 3.9 inches ID and 8 inches long, or 95.52 cubic
- inches. That works out to about 0.73 grams. However, there will be
- some volume in the motor mount tube above the motor that also must
- be accounted for, enough to nearly double the total volume when flying
- on the M1297W certification motor. Also, since this charge must fire
- reliably at 15-18k feet above ground level of around 5k feet, such
- that combustion is likely to be incomplete, we need to add some margin.
- </p><p>
- My main bay is 3.9 inches ID and about 25 inches between bulkheads,
- or about 298.50 cubic inches. That works out to 2.28 grams.
- </p><p>
- Sanity checking, PerfectFlite recommends that a 4F black powder charge
- be sized by multiplying the volume of the bay in cubic inches by 0.01
- grams. That yields about 1.8 grams for the drogue bay and 3 grams for
- the main bay.
- </p><p>
- That suggested to me that a good starting point for ground testing is
- 1.5 grams for the drogue bay and 2.5 grams for the main bay. Ground
- tests were done using the PC interface cable for the MAWD routed in
- through the static test port to manually trigger ejections. Testing
- of the apogee bay showed that 1.5 grams was sufficient for deployment
- and 1.8 grams was more authoritative. A single test of main deploy
- with 2.5 grams gave a nearly perfect result.
- Given the altitude of our expected apogee, we should be generous with
- the apogee charge, perhaps using 2.0 grams for the primary. The main
- will deploy at an altitude below where the tests were performed, so
- no adjustment in charge size should be required.
- </p><p>
- Descent rate of the nose cone and payload bay which mass just under
- 1kg will be less than 20 feet per second with a 36 inch chute based
- on manufacturer recommendations and Rocksim v8 simulation.
- Descent rate of the remainder of the rocket under the 8 foot chute
- should be about 18 feet per second by the spreadsheet provided by
- the designers of this chute pattern, sanity checked using the descent
- rate tables of similar commercial parachute designs, like those from
- The Rocketman.
- </p></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2585586"></a>Chapter 5. Stability Evaluation</h2></div></div></div><p>
- Simulation using Rocksim v8 with a variety of motors showed that the
- rocket is unconditionally stable with all motors likely to be flown.
- The worst-case stability among 75mm motors is actually with the
- M1297W chosen for the certification flight, at margin 1.05. This is
- because the front of this motor falls almost exactly at the CP. Using
- a longer motor like the M1850W raises the initial stability margin to
- 1.10 because the front fuel grain is ahead of the CP, and lesser
- motors also increase the stability because less mass is behind the CP.
- The smallest motor I can conceive of flying in this rocket (a Cesaroni
- J285) would leave us overstable with margin 3.79 on the way to about
- 1800 feet apogee.
- </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2606777"></a>Chapter 6. Expected Performance</h2></div></div></div><p>
- On the certification flight, using an Aerotech M1297W reload and
- associated hardware, the anticipated apogee is round 14,700 feet. This
- is just under 75% of the NCR North Site standing waiver of 20,000 feet.
- </p><p>
- The highest altitude simulated would be achieved with an Aerotech
- M1850W reload at nearly 18,000 feet. The lowest altitude simulated
- is with a Cesaroni J285 and Slimline adapters to just over 1800 feet.
- </p><p>
- add description of anticipated flight profile here, including launch
- weight, estimated drag coefficient, velocity leaving the rail, max
- expected velocity, altitude, and acceleration
- </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2611290"></a>Chapter 7. Checklists </h2></div></div></div><div class="orderedlist"><ol type="1"><li>
- Planning
- <div class="orderedlist"><ol type="1"><li>
- Pick a club launch with suitable waiver and facilities to
- support flight.
- </li><li>
- Confirm L3CC member(s) available to attend selected launch.
- </li><li>
- Confirm that required loaner motor hardware will be available at launch.
- </li><li>
- Notify launch sponsor (club president) of intended flight.
- </li><li>
- Notify interested friends of intended flight.
- </li><li>
- Perform final pre-flight simulation with as-built masses, etc.
- </li><li>
- Gather consummables and tools required to support flight
- <div class="orderedlist"><ol type="1"><li>
- fresh 9V batteries
- </li><li>
- black powder
- </li><li>
- e-matches
- </li><li>
- motor retainer snap rings
- </li><li>
- small nylon wire ties
- </li><li>
- cellulose wadding material
- </li><li>
- masking tape
- </li><li>
- screwdriver for phillips-head airframe screws
- </li><li>
- small straight-blade screwdriver for power switches
- </li><li>
- motor reload kit
- </li><li>
- high temperature grease
- </li><li>
- long small diameter dowels for igniter insertion
- </li></ol></div></li></ol></div></li><li>
- Before Leaving Home
- <div class="orderedlist"><ol type="1"><li>
- program altimeters for suitable mach delay and recovery deployment
- <div class="itemizedlist"><ul type="disc"><li>
- MAWD
- <div class="itemizedlist"><ul type="circle"><li>
- 8 seconds mach delay
- </li><li>
- 1500 foot main deploy
- </li></ul></div></li><li>
-
- miniRRC2
- <div class="itemizedlist"><ul type="circle"><li>
- 8 seconds mach delay
- </li><li>
- 1000 foot main deploy
- </li><li>
- 2 seconds apogee delay
- </li><li>
- no main delay
- </li><li>
- dual deploy
- </li><li>
- ops mode 16 (default)
- </li></ul></div></li></ul></div></li><li>
- assemble all recovery system components and ensure everything fits
- </li><li>
- confirm wiring and operation of altimeter power and safe/arm switches
- </li><li>
- Ground test recovery system to confirm suitable black powder
- charge sizing
- </li></ol></div></li><li>
- Pre-Flight
- <div class="orderedlist"><ol type="1"><li>
- confirm payload batteries in good condition, bay loaded, power switch works
- </li><li>
- confirm reception of signals from transmitter(s) in payload bay
- </li><li>
- install fresh 9V batteries for altimeters on avionics bay sled
- </li><li>
- inspect altimeters and associated avionics bay wiring for visible faults
- </li><li>
- close up avionics bay
- </li><li>
- install e-matches, confirming resistance of 1-2 ohms and fit in charge cups
- </li><li>
- power up altimeters, operate safe/arm switch, and confirm e-match continuity
- </li><li>
- load BP charges into charge cups
- <div class="orderedlist"><ol type="1"><li>
- Drogue Primary Charge - 2.0 grams 4F BP
- </li><li>
- Drogue Backup Charge - 2.5 grams 4F BP
- </li><li>
- Main Primary Charge - 2.5 grams 4F BP
- </li><li>
- Main Backup Charge - 3.0 grams 4F BP
- </li></ol></div></li><li>
- connect recovery harnesses and install recovery bay airframe sections
- </li><li>
- power up altimeters, operate safe/arm switch, and confirm e-match continuity
- </li><li>
- safe and power-down the altimeters
- </li><li>
- load main recovery bay, attaching nosecone and payload bay assembly
- </li><li>
- install nylon 2-56 screws as shear pins between main bay and payload bay
- </li><li>
- load drogue recovery bay, feeding harness end through fin can motor tube
- </li><li>
- install nylon 2-56 screws as shear pins between drogue bay and fin can
- </li><li>
- load motor per manufacturer instructions
- </li><li>
- attach forged eye-bolt to forward closure if not already present
- </li><li>
- attach drogue harness to eye-bolt on forward motor closure
- </li><li>
- install motor in motor mount
- </li><li>
- install motor retention snap rings
- </li><li>
- prepare igniter for later installation by attaching to long 1/8" dowel
- </li><li>
- confirm all screws in place, avionics off and safe
- </li><li>
- fill out a launch card
- </li><li>
- notify RSO/LCO of readiness for inspection and launch, obtain a rail
- assignment and permission to move rocket to launch pad for final prep
- </li><li>
- coordinate readiness with support team members, photographers, observers
- </li></ol></div></li><li>
- Final Prep
- <div class="orderedlist"><ol type="1"><li>
- move rocket to launch area
- </li><li>
- clean and lubricate launch rail if necessary
- </li><li>
- power up payload and confirm reception of signals from transmitter(s)
- </li><li>
- mount rocket on launch rail, rotate to vertical
- </li><li>
- power up primary altimeter, confirm expected beep pattern
- </li><li>
- power up backup altimeter, confirm expected beep pattern
- </li><li>
- arm ejection charges
- </li><li>
- confirm altimeters both giving expected beep patterns for igniter continuity
- </li><li>
- install igniter and connect to launch control system
- </li><li>
- capture GPS waypoint for rail location
- </li><li>
- smile for the cameras, make sure we have enough "foil Murphy!" shots taken
- </li><li>
- retreat to safe area behind LCO
- </li><li>
- confirm continued reception of transmitter signal(s) from payload bay
- </li><li>
- confirm photographers and observers are ready and know what to expect
- </li><li>
- make sure binoculars and backpack with water and recovery tools are at hand
- </li><li>
- tell RSO and LCO we're ready to launch
- </li><li>
- try to relax and enjoy watching the flight!
- </li></ol></div></li><li>
- Recovery
- <div class="orderedlist"><ol type="1"><li>
- track rocket to landing site
- </li><li>
- capture GPS waypoint of landing site, take lots of photos
- </li><li>
- note any damage
- </li><li>
- gather up and roughly re-pack recovery system for return to flight line
- </li><li>
- bring the rocket to observers for post-flight inspection
- </li></ol></div></li></ol></div></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2610811"></a>Chapter 8. Flight Summary</h2></div></div></div><p>
- YikStik was flown on an M1297W on Saturday morning at NCR's Oktoberfest
- 2008. The boost was beautiful. Unfortunately, we lost visual as the
- rocket climbed into high clouds near apogee. Radio tracking signals
- remained strong for several minutes, then disappeared. We were
- confused by viewing what we thought was YikStik descending before
- signals were lost in about the right direction, but now believe we
- were actually watching a previously launched rocket and did not see
- YikStik descend. This confusion prevented location of any of the
- rocket until Sunday evening, after I had left the launch area.
- </p><p>
- After an extensive search, the nose cone assembly was finally found
- with the Walston tracking gear nearly 3.5 miles down range. The
- remainder of the rocket has not been found despite extensive searching
- on the ground and from the air.
- </p><p>
- Reward if returned posters were placed in the area during the week
- following the launch but have elicited no useful reponses yet.
- </p></div><div class="chapter" lang="en"><div class="titlepage"><div><div><h2 class="title"><a name="id2607490"></a>Chapter 9. Analysis and Conclusions</h2></div></div></div><p>
- Consideration of how the nose cone ended up where it did suggests
- we may have had an apogee deployment of the main, perhaps due to
- stress on the shear pins before launch, during boost, or during
- apogee drogue deployment causing them to break early.
- </p><p>
- It is unfortunate that we were confused by seeing another rocket
- descending about the expected amount of time after YikStik's launch
- in approximately the right direction. This caused us to believe that
- the rocket was much closer than the nose cone turned out to be, causing
- us to waste a lot of time searching in an area too close to the launch
- site.
- It also caused us to assume something really weird had happened to the
- transmitters, such that the tracking signal was suddenly lost long
- after the rocket was on the ground, instead of what seems to really
- have happened, which is that the rocket was farther away descending
- after a main deployment at apogee, and the loss of signal was simply
- due to dropping below a ridge line a couple miles from the launch site.
- I can't help but think that if we'd been
- looking in the right area sooner after the launch that we might have
- found the rocket before someone else apparently picked it up.
- </p><p>
- I regret the decision to use a "free bag" configuration of the
- deployment bag.
- Since both tracking transmitters were in the payload bay behind
- the nose cone, and we were eventually able to recover that portion
- of the rocket, it is possible that if the deployment bag were tethered
- to the main that we might have recovered the remainder of the rocket.
- </p><p>
- If the rocket is recovered and able to fly again, the two changes I
- would like to make are to tether the deployment bag to the apex of the
- main, and to move from 2-56 nylon screws to 4-40 nylon screws for the
- main deployment shear pins, ensuring the holes through the airframe
- are a loose enough fit to avoid stresses on the pins during boost. I
- have no way to know what happened for sure, but believe this might
- solve the assumed problem of main deployment at apogee.
- </p><p>
- All in all, the design and build process was educational, and a lot
- of fun! I'm looking forward to fabricating more custom parts using
- carbon fiber and vacuum bagging in the future.
- The beautiful boost and obvious survival of the rocket airframe
- through the expected mach transitions confirms my design and
- construction skills are adequate to attain an L3 cert.
- While I hope to recover the remainder of YikStik someday, I won't
- waste any time before trying again with a new airframe!
- </p><p>
- [update] We have learned that one of the altimeters used in this
- flight, the Missile Works miniRRC2, was subject to a fault in
- firmware that could cause premature ejection of the main
- in flights above 10k feet. Thus, it now seems even more likely
- that we sustained an apogee ejection of the main, but that it
- may well have been through no fault of the rocket's design,
- construction, or preparation. Frustrating!
- </p></div></div></body></html>