{"id":1260,"date":"2009-11-08T12:09:10","date_gmt":"2009-11-08T20:09:10","guid":{"rendered":"http:\/\/www.rocketsnw.com\/?page_id=1260"},"modified":"2009-11-11T23:43:56","modified_gmt":"2009-11-12T07:43:56","slug":"david-randalls-level-3-construction-and-recovery-documentation","status":"publish","type":"page","link":"https:\/\/northwestrocketry.com\/?page_id=1260","title":{"rendered":"David Randall&#8217;s Level 3 Construction and Recovery Documentation"},"content":{"rendered":"<p align=\"center\"><strong>Polecat Aerospace Thumper \u201cAirborne Chris Craft\u201d<\/strong><\/p>\n<p align=\"center\"><strong>Level 3 Construction and Recovery Package<\/strong><\/p>\n<p align=\"center\"><strong>\u00a0<\/strong><\/p>\n<p align=\"center\"><strong>\u00a0<\/strong><\/p>\n<p align=\"center\"><strong>by<\/strong><\/p>\n<p align=\"center\"><strong>David Randall<\/strong><\/p>\n<p align=\"center\"><strong>NAR #84939 \u2013 L2<\/strong><\/p>\n<p align=\"center\"><strong>May 10th, 2008<\/strong><\/p>\n<h1>Introduction<\/h1>\n<p>This document comprises the construction package and recovery package for my NAR level 3 certification project.\u00a0 For my level 3 certification attempt I will be constructing a Polecat Aerospace Thumper rocket from a kit.\u00a0 This document will outline the materials and techniques I will be using.<\/p>\n<p>This rocket consists of one body section plus an electronics bay.\u00a0 The four fins are of reasonably standard design, and the nosecone is a mold formed fiberglass 5-1 ogive design.\u00a0 The coupling and overall construction plan for the main body, electronics bay and nosecone utilizes the manufacturer recommended construction guidelines.<\/p>\n<h1>Specifications<\/h1>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Length:<\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 7\u2019 6\u201d<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Diameter: \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/strong>Payload section: 13\u201d<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Weight:<\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 25 lbs. without motor<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Motor:<\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Aerotech M-1297<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Motor Mount<\/strong>\u00a0\u00a0 98 MM (75mm adapter used to size down)<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Altimeters:\u00a0\u00a0\u00a0\u00a0\u00a0 <\/strong>GWiz HCX (main)<\/p>\n<p>GWiz HCX (backup)<\/p>\n<p><sup>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/sup><strong>Parachute:\u00a0\u00a0\u00a0\u00a0\u00a0 <\/strong>Main: Rocketman R19C \u2013 estimated descent rate 11 fps @ 50 lbs<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Drogue: Spherachute 60\u201d \u2013 estimated descent rate 30 fps @ 50 lbs<\/p>\n<p><strong>Construction:\u00a0 <\/strong>Body Tubes: Cardboard (sonotube)<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Fins: 3\/8\u201d Birch plywood<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Centering rings: 3\/8\u201d Birch plywood<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Nose cone: Fiberglass<\/p>\n<p><strong>Reinforcement: <\/strong>Airframe &#8211; Aerosleeve fiberglass sleeve<\/p>\n<p>Fins \u2013 22\u201d x 3\u201d 2oz fiberglass strips<\/p>\n<p>Airframe couplers \u2013 6oz fiberglass cloth<\/p>\n<p>Nose Cone \u2013 Internal centering ring based reinforcement at shoulder<\/p>\n<p>\u00a0<\/p>\n<p>See the Thumper dimensions diagram in the Thumper Technical Drawings document for the major dimensions.<\/p>\n<h1>Construction Materials<\/h1>\n<h2><em>Payload body tube<\/em><em>\u00a0<\/em><\/h2>\n<p>The payload body tube will be 10.125\u201d ID cardboard tubing supplied with the kit.\u00a0 The payload body tube is a total of 13\u201d in length and will be comprised of one piece.\u00a0 The payload body tube will be secured to the altimeter bay with four #8-32 stainless screws.\u00a0 The payload body tube will be covered in a single Aerosleeve fiberglass sleeve and epoxied in place.<\/p>\n<h2><em>Main body tube<\/em><em>\u00a0<\/em><\/h2>\n<p>The main body tube will be made from 10.125\u201d ID cardboard tubing (sonotube).\u00a0 The main body tube will be 48\u201d long.\u00a0 The entire main body tube will be covered in a single Aerosleeve fiberglass sleeve and secured with epoxy.\u00a0 A layer of decorative \u201cChromaveil\u201d will be applied to the exterior of the body tube and secured with epoxy.<\/p>\n<h2><em>Fins<\/em><em>\u00a0<\/em><\/h2>\n<p>The fins are made from 3\/16\u201d birch plywood.\u00a0 The fins consist of a single piece of plywood each. \u00a0The fins will be attached to the body tube using through the wall fin construction and reinforced with an epoxy\/chopped fiber fillet on the motor tube to fin attach point, the fin to centering ring attach point, and fillets are used on the fin to body tube outer attach point. Then, 4 oz fiberglass tape will be epoxied to each fillet to motor mount joint for further reinforcement. Dado slots will be made in the centering rings to ensure proper alignment of the fins, and to provide additional epoxy surface area.\u00a0 Expanding foam will be placed in the fin\/body tube cavities to provide additional support and reinforcement.\u00a0 The fins will be finished with a wood stain and covered with a marine shellac gloss finish.<\/p>\n<h2><em>Centering rings and bulkheads<\/em><em>\u00a0<\/em><\/h2>\n<p>All centering rings and bulkheads will be made from 3\/8\u201d Baltic birch.\u00a0 The centering ring and bulkhead schedule is as follows:<\/p>\n<ul>\n<li>1 bulkhead plate for the nosecone<\/li>\n<li>1 centering ring for the nosecone<\/li>\n<li>2 centering rings for the motor mount<\/li>\n<li>2 airframe bulkhead plates for the altimeter bay<\/li>\n<\/ul>\n<h2><em>Rail guides<\/em><em>\u00a0<\/em><\/h2>\n<p>The rocket will use (large) Series 1500 5\/16\u201d slot rail buttons (<a href=\"http:\/\/www.railbuttons.com\/\">www.railbuttons.com<\/a>) as the launch pad interface. The forward rail button will be secured and epoxied to the forward end of the main airframe at the junction of the forward motor mount centering ring.\u00a0 The aft rail button will be secured and epoxied to the aft end of the main airframe at the junction of the aft motor mount centering ring.<\/p>\n<h2><em>Reinforcement materials\/Adhesives<\/em><em>\u00a0<\/em><\/h2>\n<p>As noted in the above tube sections reinforcement will be Aerosleeve fiberglass sleeve.\u00a0 TAP Plastics 4-1 super hard cure epoxy will be used for securing the fabric as well as all other glued surfaces.\u00a0 Chopped fiberglass, West Systems 410 Fairing Filler, Cab-O-Sil and milled fiberglass are all used as fillers or additive reinforcement in the project.<\/p>\n<h2><em>Nosecone<\/em><em>\u00a0<\/em><\/h2>\n<p>The nosecone material is fiberglass and pre-made from a mold by the manufacturer.\u00a0 The internal structure will be reinforced with a 3\/8\u201d plywood bulkhead epoxied to the interior of the nosecone.\u00a0 It is installed forward of the shoulder of the nosecone to provide protection against tearout during an abnormally high speed deployment.<\/p>\n<h1>Recovery System<\/h1>\n<h2><em>Deployment sequence<\/em><em>\u00a0<\/em><\/h2>\n<p>This project will utilize dual deployment for the recovery of the rocket.\u00a0 Two GWiz HCX altimeters will be used to control chute ejection.\u00a0 Each unit will be configured for dual deployment and the second HCX will act as a redundant system to the first HCX.<\/p>\n<ul>\n<li>Rocket lifts off and attains apogee<\/li>\n<\/ul>\n<ul>\n<li>The first GWiz HCX acting as primary altimeter will sense apogee and ignite the drogue ejection charge.\u00a0<\/li>\n<li>The second GWiz HCX acting as backup altimeter will sense apogee, and after a .75 second pre-configured delay, will ignite its drogue ejection charge.<\/li>\n<li>The ejection charge will separate the main section and payload section and deploy the drogue chute from the aft payload bay.<\/li>\n<li>The rocket will quickly descend in a controlled manner to an altitude of 1,500 feet.<\/li>\n<li>The first GWiz HCX acting as primary altimeter will sense the altitude and ignite the main ejection charge.\u00a0 The ejection charge will eject the nose cone and the main chute will deploy.<\/li>\n<li>The second GWiz HCX acting as backup altimeter will sense the altitude and after a .75 second pre-configured delay, ignite the main ejection charge.<\/li>\n<\/ul>\n<h2><em>Hardware<\/em><em>\u00a0<\/em><\/h2>\n<p>3\/8\u201d (forward motor mount centering ring) or \u00bc\u201d (electronics bay and nosecone) U bolts will be used to secure the recovery harnesses to the rocket airframe sections.\u00a0 These will be mounted to the bulkhead plates on the fore and aft locations of the altimeter bay, the forward bulkhead of the main body section, and the nosecone.\u00a0 All U-Bolts will use the strap on the underside of the bulkhead or centering ring for maximum tear strength. 5\/16\u201d quick links will be used to connect the recovery harnesses and parachutes.\u00a0<\/p>\n<h2><em>Parachutes<\/em><em>\u00a0<\/em><\/h2>\n<p>The drogue parachute will be a Giant Leap Sphere-a-Chute 60\u201d diameter parachute.\u00a0 The main chute will be a Rocketman R18C 216\u201d diameter parachute.<\/p>\n<h2><em>Recovery harness<\/em><em>\u00a0<\/em><\/h2>\n<p>The recovery harness will consist of 3\/8\u201d tubular nylon and \u00bd\u201d tubular nylon.\u00a0 There will be six pieces totaling 110\u2019 in length.\u00a0 The \u00bd\u201d nylon harness will measure 10\u2019 and the 3\/8\u201d tubular nylon pieces will measure 50\u2019.\u00a0 The harnesses will attach to the u-bolts and quick links using knots.\u00a0 The tested peak load of 3\/8\u201d tubular nylon is approximately 650 lbs (<a href=\"http:\/\/www.rocketmaterials.org\/datastore\/cord\/\">http:\/\/www.rocketmaterials.org\/datastore\/cord\/<\/a>).<\/p>\n<h2><em>Parachute Bays<\/em><em>\u00a0<\/em><\/h2>\n<p>The rocket will have two parachute bays, one each for the main and drogue parachutes. The main parachute bay is formed by the nosecone and electronics bay coupling. The drogue parachute bay is formed by the main body tube.\u00a0 The joint between the main body tube and the electronics bay will be held together using four shear pins.\u00a0 The joint between the electronics bay and the nosecone will be held together using four shear pins. The shear pins will be #2 nylon screws.\u00a0 Ground testing verified the shear pins functioned properly.<\/p>\n<p>The tubular nylon recovery harnesses and parachutes will be protected from ejection charge gasses using an ironing board cover formed into a deployment bag.\u00a0<\/p>\n<h2><em>Descent Rates<\/em><em>\u00a0<\/em><\/h2>\n<p>The descent rates for the parachutes are based on Rocketman Enterprises Inc and Giant Leap manufacturer\u2019s published descent rates;<\/p>\n<ul>\n<li>Giant Leap 60\u201d Spherachute drogue: 30-40 fps<\/li>\n<li>Rocketman R18C main chute: 10-12 fps<\/li>\n<\/ul>\n<p align=\"left\">Using the descent calculator found at <a href=\"http:\/\/www.aeroconsystems.com\/tips\/descent_rate.htm\">http:\/\/www.aeroconsystems.com\/tips\/descent_rate.htm<\/a> a descent rate of 11 ft\/sec using a weight of 960oz, 216 inches for the diameter of main chute, and 60 inches for the diameter of the drogue as the inputs.<\/p>\n<p>\u00a0<\/p>\n<h2><em>Altimeters<\/em><em>\u00a0<\/em><\/h2>\n<p>This rocket will use two GWiz HCX altimeters.\u00a0 One unit will be used to ignite the primary main and drogue chute charges and the second unit will be used to ignite the backup charges.\u00a0 Each unit uses barometric pressure sampling and accelerometers to sense key events during flight.\u00a0 The units will be powered by a standard 9 volt dry cell as per the manufacturer\u2019s recommendation.\u00a0 A brand new battery will be installed in each unit before flight.\u00a0 The manufacturer\u2019s software will be loaded and connected to each altimeter prior to flight, and the pyro and CPU battery voltages will be read to ensure sufficient power is present with the installed batteries.<\/p>\n<h2><em>Electronics Mounting<\/em><em><\/em><\/h2>\n<p>A plywood board will be used to mount all electronics and switches.\u00a0 The plywood board will be inserted into a set of wooden guide rails epoxied to the inside walls of the electronics bay.\u00a0 Slots in the forward and aft electronics bay bulk plates will receive the plywood to secure the plywood from movement.\u00a0<\/p>\n<p>One DPDT switch mounted in the altimeter bay electronics sled will be used to safe the primary and backup main chute ejection charges.\u00a0 One DPDT switch mounted in the altimeter bay electronics sled will be used to safe the primary and backup drogue chute ejection charges.\u00a0 One DPDT switch mounted on the electronics board will be used to control pyro power and CPU power to the main GWiz HCX flight computer.\u00a0 One DPDT switch mounted on the electronics board will be used to control pyro power and CPU power to the backup GWiz HCX flight computer.\u00a0 The flight computers will be mounted with screws to the plywood inside the altimeter bay.\u00a0<\/p>\n<p>The batteries will be mounted in plastic 9V battery cases.\u00a0 An aluminum strip is mounted to the threaded rods by nuts and washers and pressed against the main battery casing to prevent any side to side movement.\u00a0 The batteries will rest against a hard rubber stopper mounted on the aft electronics bay bulk plate to prevent any vertical motion. \u00a0<\/p>\n<h2><em>Electronics Wiring<\/em><em><\/em><\/h2>\n<p>The main GWiz HCX altimeter is powered in a dual battery configuration.\u00a0 The positive lead from each 9V battery runs through a DPDT switch.\u00a0 The negative lead from each 9V battery runs directly to the altimeter.\u00a0 There are three pyro outputs wired to the altimeter.\u00a0 The first pyro output is for apogee deployment, and one lead of the e-match is wired through a DPDT switch for mechanically disabling current to the e-match.\u00a0 The second pyro output is for low altitude main chute deployment, and one lead of the e-match is wired through a separate DPDT switch for mechanically disabling current to the e-match.\u00a0\u00a0 The third pyro port is used for a smoke canister ignited by electric match.\u00a0 It will ignite at 2 seconds after motor burnout for tracking purposes.<\/p>\n<p>The backup GWiz HCX altimeter is powered in a dual battery configuration.\u00a0 The positive lead from each 9V battery runs through a DPDT switch.\u00a0 The negative lead from each 9V battery runs directly to the altimeter.\u00a0 There are two pyro outputs wired to the altimeter.\u00a0 The first pyro output is for apogee deployment, and one lead of the e-match is wired through a DPDT switch for mechanically disabling current to the e-match.\u00a0 The second pyro output is for low altitude main chute deployment, and one lead of the e-match is wired through a separate DPDT switch for mechanically disabling current to the e-match.\u00a0<\/p>\n<h2><em>Wiring Diagram<\/em><em><\/em><\/h2>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\">Figure 1 &#8211; Wiring Diagram &#8211; Altimeters<\/p>\n<p>\u00a0<\/p>\n<h2><em>Pyrotechnics<\/em><em><\/em><\/h2>\n<p>The purpose of the ejection charges is to separate the payload bays from the main and nose cone and deploy the parachutes.\u00a0 The amount of black powder needs to be enough to break the shear pins, separate the airframe sections, and eject the parachutes enough so they inflate and slow the rocket for a safe recovery.<\/p>\n<p>The rule of thumb for sizing ejection charges is to generate 15 psi of force acting against the bulk plates to separate the components of the rocket.\u00a0 However, for larger rockets this amount of pressure will be too much since the area this pressure acts on increases with the diameter.\u00a0 The target force required to separate components of the rocket is 350 pounds of force.\u00a0 Assuming 15psi were generated by a charge.\u00a0 Because the 10\u201d airframe sections have 78 square inches of area at the ends, the total applied force would be 1,170 pounds of force (78 in<sup>2<\/sup> * 15psi).\u00a0 This is too much, and may result in high speed separation or failure of the airframe, rather than proper separation.\u00a0 In solving for the amount of black powder to use, a target of 350 pounds of force will be used rather than pressure.<\/p>\n<p>\u00a0<\/p>\n<p>There will be four ejection charges used in this rocket; one primary charge each for main and drogue chute ejection and one back up charge each.\u00a0 The size of the primary ejection charges is calculated using the below equation to solve for the amount of force needed.<\/p>\n<p>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0<\/p>\n<p><strong>m=F*(L)\/R\/T\/12 * 464<\/strong><\/p>\n<p><strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/strong><\/p>\n<ul>\n<li>m = mass of BP needed in grams<\/li>\n<li>F = specified force in lbf<\/li>\n<li>L = length of pressurized compartment in inches<\/li>\n<li>R = Gas constant = 22.16 ft*lbf\/lbm<\/li>\n<li>T = combustion temperature constant = 3307<\/li>\n<\/ul>\n<p>Using this equation the ejection charge sizes are:<\/p>\n<ul>\n<li>Drogue chute:\u00a0 F = 350, L = 20\n<ul>\n<li>m =\u00a0 (350*20)\/22.16\/3307\/12 * 464 = 3.7<strong> grams<\/strong><\/li>\n<li>Main Chute: F = 350, L = 7\n<ul>\n<li>m =\u00a0 350*(7)\/22.16\/3307\/12 * 464 = 1.3<strong> grams<\/strong><\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<p>\u00a0<\/p>\n<p>Using a simplified equation found at http:\/\/www.vernk.com\/EjectionChargeSizing.htm verifies this amount.<\/p>\n<p>\u00a0<\/p>\n<p><strong>N = 0.00052*FL<\/strong><\/p>\n<p>\u00a0<\/p>\n<ul>\n<li>N = grams of black powder<\/li>\n<li>F = Specified force in pounds<\/li>\n<li>L = Length of pressurized compartment<\/li>\n<\/ul>\n<p>\u00a0<\/p>\n<ul>\n<li>Drogue chute:\u00a0 F = 350, L = 20\n<ul>\n<li>N =\u00a0 .00052 * 350 * 20 = 3.64<strong> grams<\/strong><\/li>\n<li>Main Chute: F = 350, L = 7\n<ul>\n<li>N =\u00a0 .00052 * 350 * 7 = 1.27<strong> grams<\/strong><\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<p>Each of the ejection charges will be ignited using e-matches.\u00a0 The backup ejection charges will be increased by 50% to add an additional margin of safety.<\/p>\n<h1>Stability Evaluation<\/h1>\n<h2><em>Ground Support Equipment<\/em><em><\/em><\/h2>\n<p>The estimated minimum velocity for stable flight is 44 ft\/sec and using Rocksim 8.0 the rocket will achieve this velocity at 45\u201d or just under four feet.\u00a0 Since eight feet is the minimum distance for minimum stable velocity, a standard eight foot launch rail will be used.\u00a0 The estimated velocity at the end of an eight foot rail will be 75 ft\/sec.\u00a0 These calculations are based on an Aerotech M1297 motor.<\/p>\n<h2><em>Center of Pressure\/Center of Gravity<\/em><em><\/em><\/h2>\n<p>The calculated center of pressure using Rocksim v8.0 is 64.3\u201d.\u00a0 The measured center of gravity is 43 inches without the motor which results in a static margin of 2.1 calibers.\u00a0 Loaded with an AT M1297 the static margin drops to 1.37 calibers which still provides for a stable flight.<\/p>\n<h2><em>Flight Profile<\/em><em><\/em><\/h2>\n<p>Launch Weight: \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 47 lbs.<\/p>\n<p>Motor:\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Aerotech M1297W<\/p>\n<p>Calculated Launch velocity:\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 63 ft\/sec<\/p>\n<p>Maximum Calculated Velocity:\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 657 ft\/sec<\/p>\n<p>Maximum Calculated Altitude:\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 5497 ft<\/p>\n<p>Maximum Calculated Acceleration:\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 1022 ft\/sec\/sec<\/p>\n<p>Rocksim v8.0 was used to calculate the flight parameters.<\/p>\n<p>\u00a0<\/p>\n<h1>Construction Techniques<\/h1>\n<h2><em>Motor Mount\/Fin Assembly<\/em><em><\/em><\/h2>\n<p>The motor mount\/fin assembly will be built and then slid into the main body tube as a single unit.\u00a0 This method of construction will allow easy access to apply epoxy fillets and internal reinforcement to all fin\/motor mount joints.\u00a0 Fin mounting will be through the wall construction.<\/p>\n<h3>Materials<\/h3>\n<p>1 \u2013 48\u201d 98mm motor mount<\/p>\n<p>2 \u2013 3\/8\u201d x 10.125\u201d O.D. x 4\u201d I.D plywood centering rings<\/p>\n<p>1 \u2013 Aero Pack 98mm motor retainer<\/p>\n<p>4 \u2013 22\u201d x 11\u201d main fins<\/p>\n<p>Chopped Fiberglass Fibers<\/p>\n<p>4 oz Fiberglass cloth tape<\/p>\n<p>TAP 4-1 Super Hard Epoxy<\/p>\n<h3>Fin Can Sub-assembly<\/h3>\n<p>1)\u00a0\u00a0\u00a0 For the fins and centering rings I used the parts included with the kit, but performed a minor modification.\u00a0 Each centering ring was slotted for the fins to provide additional rigidity and ensure a true 90\u00b0 alignment. \u2013 See <strong>Error! Reference source not found.<\/strong> and Figure 2 &#8211; Fins in Dado Slots for alignment. I prepared epoxy with chopped fiberglass and applied it to the tab and slots of the pieces for each of the four fins.\u00a0 I applied the epoxy with chopped fiberglass as fillets to all the joints. The assembly was set aside to cure at room temperature. \u00a0I applied 4 oz fiberglass \u201ctape\u201d to the fillets to provide additional joint strength.\u00a0 See Figure 3 &#8211; Fiberglass tape applied to fin mount points. The assembly was set aside to cure at room temperature.\u00a0<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>2 &#8211; Fins in Dado Slots for alignment<\/strong><\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>3 &#8211; Fiberglass tape applied to fin mount points<\/strong><\/p>\n<h3>Motor Retention<\/h3>\n<p>1)\u00a0\u00a0\u00a0 At the end of the motor mount tube I secured the 98mm Aero Pack motor retainer using the supplied screws and manufacturer instructions.\u00a0<\/p>\n<p>\u00a0<\/p>\n<h2><em>Body tube<\/em><em><\/em><\/h2>\n<h3>Materials<\/h3>\n<p>1 &#8211; 48\u201d x 10\u201d airframe<\/p>\n<p>Aerosleeve 6 oz fiberglass sleeving<\/p>\n<p>Chromaveil decorative fabric<\/p>\n<p>West Systems 410 fairing filler<\/p>\n<p>1 \u2013 Motor Mount assembly<\/p>\n<p>TAP Plastics 4-1 super hard epoxy<\/p>\n<h3>Airframe<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The main airframe is composed of one piece of 10\u201d ID airframe tube.\u00a0 The length is 48 inches.\u00a0 The entire length of the main was reinforced with a single length of Aerosleeve 6 oz fiberglass. See Figure 4 &#8211; Applied epoxy and fiberglass sleeve. \u00a0The tube was wrapped with a 1 mil acetate film and wrapped with stretchable plastic wrap.\u00a0 This was set to cure for two days.\u00a0 The 1 mil acetate was removed and a mixture of West Systems 410 fairing filler and TAP Plastics 4-1 super hard epoxy was applied with a spreader directly to the tube to fill in any pinholes or ridges left from the stretchable plastic wrap.\u00a0 This was set to cure for 2 days.\u00a0 Next, a layer of Chromaveil (decorative cloth finish) was applied and a second coat of epoxy applied to the Chromaveil.\u00a0 The tube was wrapped with a 5 mil acetate film, excess epoxy was squeezed out, and the tube was set to cure.\u00a0 The 5 mil acetate film was removed after the epoxy had fully cured.<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>4 &#8211; Applied epoxy and fiberglass sleeve<\/strong><\/p>\n<p>\u00a0<\/p>\n<h3>Fin Slots<\/h3>\n<p>1)\u00a0\u00a0\u00a0 Once the main airframe lay-up had fully cured, four 3\/16\u201d slots were cut from the aft end for the fins.\u00a0 A router jig was used to ensure the slots were true and the tube remained stable through the slotting process.\u00a0 See Figure 5 &#8211; Router jig for fin slots .<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>5 &#8211; Router jig for fin slots<\/strong><\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure 6 &#8211; View of 4 fin slots<\/strong><\/p>\n<h3>Final Assembly<\/h3>\n<p>1)\u00a0\u00a0\u00a0 After the epoxy had cured the fin can sub-assembly was inserted into the body tube.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Epoxy fillets with milled fiberglass, fairing filler and Cab-O-Sil were formed on each of the four fin to body tube joints.<\/p>\n<p>3)\u00a0\u00a0\u00a0 TAP Plastics Two-Part Expanding foam was poured into fin cavities through holes drilled in the aft centering ring to provide additional rigidity.<\/p>\n<h2><em>Electronics Bay<\/em><em><\/em><\/h2>\n<p>The electronics bay will hold the two altimeters needed for the certification flight.\u00a0 For a complete wiring diagram please see Figure 1 &#8211; Wiring Diagram &#8211; Altimeters<\/p>\n<h3>Materials<\/h3>\n<p>1 \u2013 13\u201d x 10.125\u201d airframe coupler<\/p>\n<p>1 \u2013 9\u201d x 10.125\u201d airframe<\/p>\n<p>2 \u2013 10\u201d coupler bulk plates<\/p>\n<p>4 \u2013 3\/8\u201d x 15\u201d threaded rod<\/p>\n<p>16 \u2013 3\/8\u201d hex nuts<\/p>\n<p>16 \u2013 3\/8\u201d washers<\/p>\n<p>4 \u2013 3\/8\u201d U-bolts<\/p>\n<p>4 \u2013 DPDT switches<\/p>\n<p>1 \u2013 Aluminum retention strip<\/p>\n<p>2 \u2013 Four node terminal blocks<\/p>\n<p>4 \u2013 Schedule 40 end cap<\/p>\n<p>4 \u2013 #6-32 x 1\u201d bolts<\/p>\n<p>4 &#8211; #6-32 nuts<\/p>\n<p>1 \u2013 8\u201d x 6\u201d x \u00bc\u201d plywood electronics board<\/p>\n<p>1-6\u201d x 7.5\u201d fiberglass Aerosleeve<\/p>\n<p>6oz fiberglass<\/p>\n<p>West Systems Epoxy<\/p>\n<p>24 gauge solid copper wire<\/p>\n<h3>Bulk plate assembly (see Figure 7 &#8211; Electronics Bay Bulk Plate)<\/h3>\n<p>1)\u00a0\u00a0\u00a0 Four holes were drilled for the U-bolts and one hole was drilled for the pass-through of wiring to the terminal block.<\/p>\n<p>2)\u00a0\u00a0\u00a0 The terminal block mounting holes were drilled and the terminal blocks mounted.<\/p>\n<p>3)\u00a0\u00a0\u00a0 The electronics wiring was passed through the wiring hole and epoxy was applied to block air passage around the wiring.<\/p>\n<p>4)\u00a0\u00a0\u00a0 The U-bolts were installed into each of the bulk plates with the hex nuts and secured with loctite to prevent them from coming undone.<\/p>\n<p>5)\u00a0\u00a0\u00a0 Each of the airframe bulk plates were coated with epoxy to protect from ejection gasses.<\/p>\n<p>6)\u00a0\u00a0\u00a0 The 3\/8\u201d threaded rod was then placed through the holes in one of the bulk plate assemblies and secured with 3\/8\u201d nuts and loctite.<\/p>\n<p>7)\u00a0\u00a0\u00a0 Two ejection cups were epoxied in place on each of the bulk plates.\u00a0 These will hold the ejection charge during flight.<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>7 &#8211; Electronics Bay Bulk Plate<\/strong><\/p>\n<p>\u00a0<\/p>\n<h3>Coupler Tube<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The coupler tube ends were first reinforced with CA glue to prevent fraying and allow sanding of the coupler ends for proper fit-up.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Four \u00bc\u201d x \u00bc\u201d x 7\u201d wood strips were epoxied to the inside of the coupler tube.\u00a0 These are used to hold the altimeter sled in place.<\/p>\n<p>3)\u00a0\u00a0\u00a0 After the epoxy had dried four \u00bc\u201d holes were cut through the airframe and coupler for the DPDT switches.\u00a0 These switches will be used to safe the primary and backup ejection charges.\u00a0<\/p>\n<p>4)\u00a0\u00a0\u00a0 The airframe was also drilled with two \u00bc\u201d diameter holes that are used to transfer the LED light from the altimeters to the exterior of the rocket via a Plexiglas rod.<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure 8 &#8211; Slotting and Rails for Sled<\/strong><\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>9- Mounting Slots and Rail Guides<\/strong><\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>10 &#8211; Mounting of Aluminum Stop Strip<\/strong><\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure <\/strong><strong>11 &#8211; Hard Rubber Vertical Motion Stop<\/strong><\/p>\n<p>\u00a0<\/p>\n<p>\u00a0<\/p>\n<h3>Electronics bay wiring<\/h3>\n<p>1)\u00a0\u00a0\u00a0 Two sets of wires are used for the main ejection charges.\u00a0 One pair of wires (orange &amp; brown) is used for the primary main chute ejection charge, the other (red and black) are used for the backup main chute ejection charge.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Two sets of wires are used for the drogue ejection charges.\u00a0 One pair of wires (orange &amp; brown) is used for the primary drogue chute ejection charge, the other (red and black) are used for the backup drogue chute ejection charge.<\/p>\n<p>3)\u00a0\u00a0\u00a0 The wiring for the main chute ejection charge terminates with connections to a four connector terminal block on the forward end of the forward bulk plate.\u00a0<\/p>\n<p>4)\u00a0\u00a0\u00a0 The wiring for the drogue chute ejection charge terminates with connections to a four connector terminal block on the aft end of the aft bulk plate.\u00a0<\/p>\n<p>\u00a0<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure 12 &#8211; Mounted terminal block<\/p>\n<p><\/strong><\/p>\n<p align=\"center\"><strong><\/strong><\/p>\n<p align=\"center\"><strong>Figure 13 &#8211; Terminal Block Wiring<\/strong><\/p>\n<h3>Electronics board wiring<\/h3>\n<p>1)\u00a0\u00a0\u00a0 An outline was first drawn on the electronics board to show the mounting location for the altimeters, batteries, and the DPDT switches.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Each of the components was then mounted to the electronics board.\u00a0 The altimeters and DPDT switches were mounted to one side of the electronics board.\u00a0 The batteries were mounted to the opposite side of the electronics board.<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>3)<\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <strong>Figure <\/strong><strong>14 &#8211; GWiz Altimeters (HCX1 &#8211; Left, HCX2 &#8211; Right)<\/strong><\/p>\n<p>4)\u00a0\u00a0\u00a0 One wire was run from the main chute terminal on the HCX altimeter to one of the terminal block nodes.\u00a0 Another wire was run from the main chute terminal on the HCX altimeter to one of the DPDT switches.\u00a0 Another wire was run from the DPDT switch to one of the terminal block nodes.\u00a0 Wires were run from the drogue terminals on the HCX in the same manner.<\/p>\n<p>5)\u00a0\u00a0\u00a0 The positive wire from one battery (Pyro1) was connected to one of the DPDT switches.\u00a0 A wire was run from the DPDT switch to the pyro battery positive terminal on the HCX.\u00a0 The negative wire from the same battery was connected to the pyro battery negative terminal on the HCX.<\/p>\n<p>6)\u00a0\u00a0\u00a0 The same wiring method was used for the backup HCX altimeter.<\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure 15 &#8211; Altimeter side wiring<\/strong><\/p>\n<p>\u00a0<\/p>\n<p align=\"center\">\u00a0<\/p>\n<p align=\"center\"><strong>Figure 16 &#8211; Battery Side Wiring<\/strong><\/p>\n<h3>Final Assembly<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The bulk plate assembly with the threaded rod was inserted into one end of the electronics bay.\u00a0 The electronics board was then8 slid part way onto the threaded rod.\u00a0 Each set of wires was then connected to the outward facing nodes of the terminal blocks so that the red and black wires connected to the switches lined up with the red and black wires leading to the altimeters.<\/p>\n<p>2)\u00a0\u00a0\u00a0 The electronics board was then slid all the way into the altimeter bay.\u00a0 The bulk plate with the threaded rod was then rotated until the DPDT switches on the altimeter board were aligned with two of the vent holes.\u00a0 These vent holes will also act as the access ports for the DPDT switches.<\/p>\n<p>3)\u00a0\u00a0\u00a0 The remaining bulk plate was slid over the all thread and secured with wing nuts to ensure the proper fit of all the components.<\/p>\n<h3>Securing payload and electronics bays<\/h3>\n<p>1)\u00a0\u00a0\u00a0 Once the tubes had cured and the tape removed the tubes were placed partway onto the electronics bay and marks were made on the tubes to indicate where the screw holes needed to be.\u00a0 Then each of the airframes was drilled with six holes each for the screws to secure the airframe sections to the electronics bay.<\/p>\n<h3>Testing<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The electronics were then turned on through the access ports to ensure the DPDT switches were correctly wired.\u00a0 The manufacturer\u2019s software was used in conjunction with 12V lamps to verify the proper operation of a sample flight as well as direct manipulation of the pyro outputs.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Each altimeter goes through a diagnostic to determine continuity of the ejection charge channels and then beeps out that continuity.\u00a0 The altimeters were tested with channels bridged, drogue only, and main only to verify the wiring.\u00a0 This testing should not be confused with the actual ejection charge testing required for level 3 certification.<\/p>\n<h2><em>Payload Bays<\/em><em><\/em><\/h2>\n<p>The payload bay comprises the section above the electronics bay used to retain the main chute.<\/p>\n<h3>Materials<\/h3>\n<p>1)\u00a0\u00a0\u00a0 1 \u2013 13\u201d x 10.125\u201d airframe<\/p>\n<p>2)\u00a0\u00a0\u00a0 1 \u2013 13\u201d Aeroesleeve fiberglass sleeve<\/p>\n<p>3)\u00a0\u00a0\u00a0 4 \u2013 \u00bc\u201d tapered machine screws<\/p>\n<p>4)\u00a0\u00a0\u00a0 TAP 4-1 Super Hard Epoxy<\/p>\n<p>\u00a0<\/p>\n<h3>Reinforcement<\/h3>\n<p>1)\u00a0\u00a0\u00a0 One length of Aerosleeve was cut and placed the airframe section.\u00a0 Epoxy was then applied to thoroughly wet the fiberglass.\u00a0 A layer of 5 mil acetate plastic was wrapped around the tube.\u00a0 The excess epoxy was squeezed out by hand and then the airframe was taped to secure the acetate.\u00a0 The tube was set aside to cure.\u00a0 After curing, the acetate was removed.<\/p>\n<h3>Shear pins<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The nose cone was inserted into the main chute payload bay.\u00a0 Four equally spaced 5\/65\u201d holes were then drilled for insertion of the shear pins.<\/p>\n<p>2)\u00a0\u00a0\u00a0 Four pieces of 1\u201d x \u00bd\u201d x .025\u201d brass were drilled with a 5\/64\u201d hole.<\/p>\n<p>3)\u00a0\u00a0\u00a0 The brass pieces were epoxied in place over the holes in the nose cone shoulder and serve as a shearing point for the pins.\u00a0<\/p>\n<p>4)\u00a0\u00a0\u00a0 The drogue payload bay and the main were fitted for shear pins in the same manner<\/p>\n<p>5)\u00a0\u00a0\u00a0 #2-56 \u2013 3\/4\u201d nylon screws will act as the shear pins.<\/p>\n<p>\u00a0<\/p>\n<h2><em>Nose Cone<\/em><em><\/em><\/h2>\n<h3>Materials<\/h3>\n<p>1 \u2013 10\u201d x 3\/8\u201d plywood bulk plate<\/p>\n<p>1 \u2013 7.5\u201d x 3\/8\u201d plywood bulk plate<\/p>\n<p>1 \u2013 3\/8\u201d U-bolt<\/p>\n<p>4 \u2013 \u00bc-20 T-Nuts<\/p>\n<p>4 \u2013 \u00bc-20 bolts<\/p>\n<p>1 \u2013 3\/8\u201d all-thread \u2013 24\u201d length<\/p>\n<p>TAP 4-1 Super Hard epoxy<\/p>\n<h3>Fabrication<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The nosecone is supplied with the kit.<\/p>\n<p>2)\u00a0\u00a0\u00a0 The finished cone was lightly sanded to even out any high spots.<\/p>\n<p>3)\u00a0\u00a0\u00a0 The bulk plate was pre-drilled with two holes for the U-Bolt.\u00a0 The U-bolt was secured using the hex nuts and loctite.<\/p>\n<p>4)\u00a0\u00a0\u00a0 The bulk plate was then secured to the aft end of the nosecone with the U-bolt facing out.\u00a0 This is the connection point for the main chute recovery harness.<\/p>\n<p>5)\u00a0\u00a0\u00a0 Approximately 50cc\u2019s of epoxy was poured into the nosecone.\u00a0 A length of 3\/8\u201d all-thread was inserted into the epoxy and left to cure.\u00a0 The all-thread is used to secure weights in the nosecone to adjust the CG as required for various sized motors.<\/p>\n<h3>Nose Cone Shoulder<\/h3>\n<p>1)\u00a0\u00a0\u00a0 The nose cone shoulder had a layer of epoxy with West Systems 410 Fairing Filler applied to approximately a 1\/16\u201d depth. This allowed a tighter fit with the payload bay tubing.<\/p>\n<p>2)\u00a0\u00a0\u00a0 One centering ring was installed behind the shoulder and epoxied in place.<\/p>\n<p>3)\u00a0\u00a0\u00a0 Four holes were drilled in the centering ring and 4 blind nuts inserted in the forward end of the holes.<\/p>\n<p>4)\u00a0\u00a0\u00a0 Four holes were drilled in a bulk plate to match the centering ring.\u00a0 Four \u00bc\u201d bolts secure the bulk plate to the centering ring.\u00a0<\/p>\n<p>5)\u00a0\u00a0\u00a0 Two holes were drilled in the centering ring for the U-bolt.<\/p>\n<p align=\"left\">6)\u00a0\u00a0\u00a0 The U-bolt was installed into the bulk plates with the hex nuts and secured with loctite to prevent them from coming undone.<\/p>\n<p>\u00a0<\/p>\n<h1>1)\u00a0 \u00a0Appendix A \u2013 Diagrams<\/h1>\n<h3>Rocksim CG\/CP locations<\/h3>\n<p>\u00a0<\/p>\n<p><strong><br \/>\n<\/strong><\/p>\n<h1>2)\u00a0 Rocket under Drogue Chute<\/h1>\n<p>\u00a0<\/p>\n<p>\u00a0<\/p>\n<h1>3)\u00a0 Rocket under Main Chute<\/h1>\n<p>\u00a0<\/p>\n<p>\u00a0<\/p>\n<h1>4)\u00a0 Completed Rocket Photograph<\/h1>\n<p>\u00a0<\/p>\n<h1>5)\u00a0 Appendix B \u2013 Flight Simulation<\/h1>\n<p>The information in this section shows flight simulation data taken from RockSim v8.0.\u00a0 The simulation properties were set to reflect an Aerotech M1297W motor used for propulsion and the elevation and location figures matching those of Mansfield, Wa.<\/p>\n<p>\u00a0<\/p>\n<p><strong>L3 Thumper &#8211; Simulation results<\/strong><\/p>\n<p><strong>Engine selection<\/strong><\/p>\n<p><strong>[M1297W-None] <\/strong><\/p>\n<p><strong>\u00a0<\/strong><\/p>\n<p><strong>Simulation control parameters<\/strong><\/p>\n<p>Flight resolution: 800.000000 samples\/second<\/p>\n<p>Descent resolution: 1.000000 samples\/second<\/p>\n<p>Method: Explicit Euler<\/p>\n<p>End the simulation when the rocket reaches the ground. <strong><\/strong><\/p>\n<p><strong>Launch conditions<\/strong><\/p>\n<p>Altitude: 2262.00000 Ft.<\/p>\n<p>Relative humidity: 40.000 %<\/p>\n<p>Temperature: 70.000 Deg. F<\/p>\n<p>Pressure: 29.9139 In.<\/p>\n<p>Wind speed model: Slightly breezy (8-14 MPH)<\/p>\n<p>Low wind speed: 8.0000 MPH<\/p>\n<p>High wind speed: 14.9000 MPH<\/p>\n<p>Wind turbulence: Fairly constant speed (0.01)<\/p>\n<p>Frequency: 0.010000 rad\/second<\/p>\n<p>Wind starts at altitude: 100.00000 Ft.<\/p>\n<p>Launch guide angle: 0.000 Degrees from vertical<\/p>\n<p>Latitude: 47.800 Degrees<\/p>\n<p><strong>Launch guide data:<\/strong><\/p>\n<p>Launch guide length: 96.0000 In.<\/p>\n<p>Velocity at launch guide departure: 63.8120 ft\/s<\/p>\n<p>The launch guide was cleared at : 0.263 Seconds<\/p>\n<p>User specified minimum velocity for stable flight: 43.9993 ft\/s<\/p>\n<p>Minimum velocity for stable flight reached at: 45.5677 In.<\/p>\n<p><strong>Max data values:<\/strong><\/p>\n<p>Maximum acceleration:Vertical (y): 1022.969 Ft.\/s\/sHorizontal (x): 4.145 Ft.\/s\/sMagnitude: 1022.969 Ft.\/s\/s<\/p>\n<p>Maximum velocity:Vertical (y): 657.0833 ft\/s, Horizontal (x): 21.8533 ft\/s, Magnitude: 658.8812 ft\/s<\/p>\n<p>Maximum range from launch site: 4075.29528 Ft.<\/p>\n<p>Maximum altitude: 5467.94620 Ft. 1638.07055 Ft.<\/p>\n<p>Maximum altitude: 6814.06093 Ft.<\/p>\n<p><strong>Recovery system data<\/strong><\/p>\n<p>P: Drogue Parachute Deployed at : 18.211 Seconds<\/p>\n<p>Velocity at deployment: 30.3129 ft\/s<\/p>\n<p>Altitude at deployment: 5467.94620 Ft.<\/p>\n<p>Range at deployment: -470.98753 Ft.<\/p>\n<p>P: Main (low altitude) Parachute Deployed at : 102.734 Seconds<\/p>\n<p>Velocity at deployment: 56.2477 ft\/s<\/p>\n<p>Altitude at deployment: 999.98688 Ft.<\/p>\n<p>Range at deployment: 1273.22179 Ft.<\/p>\n<p><strong>Time data<\/strong><\/p>\n<p>Time to burnout: 4.170 Sec.<\/p>\n<p>Time to apogee: 18.211 Sec.<\/p>\n<p>Optimal ejection delay: 14.041 Sec.<\/p>\n<p>Time to wind shear: 0.912 Sec.<\/p>\n<p><strong>Landing data<\/strong><\/p>\n<h1>Successful landing<\/h1>\n<h1>Time to landing: 243.421 Sec.<\/h1>\n<h1>Range at landing: 4075.29528<\/h1>\n<h1>Velocity at landing: Vertical: -12.5951 ft\/s , Horizontal: 0.0000 ft\/s , Magnitude: 12.5951 ft\/s<\/h1>\n<p>\u00a0<\/p>\n<p>\u00a0<\/p>\n<h1>6)\u00a0 \u00a0Appendix C \u2013 Checklists<\/h1>\n<h2>Pre-Launch Checklist<\/h2>\n<p>This is the pre-launch checklist as required as part of the Level 3 procedures. This checklist is to be used on launch day while preparing the rocket for my L3 certification flight.<\/p>\n<h3>1)\u00a0\u00a0\u00a0 Paperwork Preparation (This is needed only for L3 certification attempt)<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Confirm L3 Certification Application Form has been filled out<\/p>\n<p>b)\u00a0\u00a0\u00a0 Confirm Construction Package Affidavit has been filled out and signed by a member of the L3CC<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Confirm Recovery Package Affidavit has been filled out and signed by a member of the L3CC<\/p>\n<p>d)\u00a0\u00a0\u00a0 Confirm Pre-Flight checklist has been filled out and signed by certification team<\/p>\n<p>e)\u00a0\u00a0\u00a0 Confirm one member of the certification team is a L3CC member<\/p>\n<h2>Recovery System Preparation<\/h2>\n<h3>1)\u00a0\u00a0\u00a0 Electronics<\/h3>\n<h4><strong>a)\u00a0 <\/strong><strong>Prepare <\/strong><strong>GWiz HCX1 altimeter<\/strong><strong> <\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 While flight computer is out of the rocket, connect to PC to verify configuration:<\/p>\n<p>(1)\u00a0\u00a0 Main at 1500\u2019<\/p>\n<p>(2)\u00a0\u00a0 Drogue at apogee<\/p>\n<p>(3)\u00a0\u00a0 Pyro port 4 at burnout + 2 seconds (for effect smoke canister)<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Be sure all arming switches are off.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Install two <strong><em><span style=\"text-decoration: underline;\">NEW<\/span><\/em><\/strong> batteries.<\/p>\n<p>iv)\u00a0\u00a0 Secure batteries in place with positive battery retention system.<\/p>\n<p>v)\u00a0\u00a0\u00a0 Check dip switches are set for high current per manufacturers instructions<\/p>\n<p>(1)\u00a0\u00a0 HC Switch 1 = on<\/p>\n<p>vi)\u00a0\u00a0 Ready avionics bay for altimeter.<\/p>\n<p>vii)\u00a0 Install altimeter in rocket.<\/p>\n<p>viii) Insure all pyrotechnics are in disarmed mode during electronics final installation.<\/p>\n<h4><strong>b)\u00a0 <\/strong><strong>Prepare <\/strong><strong>GWiz HCX2 altimeter<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Be sure all arming switches are off.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Install two <strong><em><span style=\"text-decoration: underline;\">NEW<\/span><\/em><\/strong> batteries.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Secure batteries in place with positive battery retention system.<\/p>\n<p>iv)\u00a0\u00a0 Check dip switches are set for high current per manufacturers instructions<\/p>\n<p>(1)\u00a0\u00a0 HC Switch 1 = on<\/p>\n<p>v)\u00a0\u00a0\u00a0 Ready avionics bay for altimeter.<\/p>\n<p>vi)\u00a0\u00a0 Install altimeter in rocket.<\/p>\n<p>vii)\u00a0 Insure all pyrotechnics are in disarmed mode during electronics final installation.<\/p>\n<p>\u00a0<\/p>\n<h3>2)\u00a0\u00a0\u00a0 Pyrotechnics<\/h3>\n<p><strong>Note:<\/strong> <strong><span style=\"text-decoration: underline;\">All pyrotechnic devices must remain in an unarmed mode until rocket is on pad ready to launch.<\/span><\/strong><\/p>\n<h4><strong>a)\u00a0 <\/strong><strong>Pyrotechnics, drogue<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Prepare drogue deployment pyrotechnic charges and ready for installation into rocket.<\/p>\n<p>(1)\u00a0\u00a0 3.6 grams <strong>OR<\/strong><\/p>\n<p>(2)\u00a0\u00a0 55 grains<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Connect drogue charge leads to wiring terminals on electronics bay<\/p>\n<h4><strong>b)\u00a0 <\/strong><strong>Pyrotechnics, main<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Prepare main deployment pyrotechnic charges and ready for installation into rocket.<\/p>\n<p>(1)\u00a0\u00a0 1.5 grams <strong>OR<\/strong><\/p>\n<p>(2)\u00a0\u00a0 23 grains<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Connect main charge leads to wiring terminals on electronics bay.<\/p>\n<p>\u00a0<\/p>\n<h3>3)\u00a0\u00a0\u00a0 Drogue Chute Preparation<\/h3>\n<h4><strong>a)\u00a0 <\/strong><strong>Inspect components.<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Check shock cords for cuts, burns, and tangles.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Check all shroud lines &#8212; no tangles.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Check drogue chute for tears and burns.<\/p>\n<p>iv)\u00a0\u00a0 Check deployment bag for tears.<\/p>\n<h4><strong>b)\u00a0 <\/strong><strong>Pack drogue chute<\/strong><strong> <\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Fold drogue chute per manufacturer&#8217;s instructions.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Insure shroud lines are free from tangles.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Insure all quick links are secure.<\/p>\n<p>iv)\u00a0\u00a0 Wrap drogue chute in chute deployment bag.<\/p>\n<p>v)\u00a0\u00a0\u00a0 Insert drogue bag\/chute into main compartment<\/p>\n<h4><strong>c)\u00a0\u00a0 <\/strong><strong>Check all connections.<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Electronics bay harness to quick link<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Drogue harness to quick link<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Drogue chute to quick link<\/p>\n<p>iv)\u00a0\u00a0 Drogue chute protection to quick link<\/p>\n<h4><strong>d)\u00a0 <\/strong><strong>Secure drogue payload bay<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Fit electronics bay on main body tube and line up holes.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Insert shear pins in holes.<\/p>\n<h3>4)\u00a0\u00a0\u00a0 Main Chute Preparation<\/h3>\n<h4><strong>a)\u00a0 <\/strong><strong>Inspect components<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Check harness for cuts, burns, and tangles.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Check all shroud lines &#8212; no tangles.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Check main chute for tears and burns.<\/p>\n<p>iv)\u00a0\u00a0 Check deployment bag for tears.<\/p>\n<h4><strong>b)\u00a0 <\/strong><strong>Check all connections<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Nose Cone harness to quick link.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Avionics bay harness to quick link.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Main chute to quick link.<\/p>\n<p>iv)\u00a0\u00a0 Main chute protection to quick link.<\/p>\n<h4><strong>c)\u00a0\u00a0 <\/strong><strong>Pack main chute<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Fold main chute per manufacturer&#8217;s instructions.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Insure shroud lines are free from tangles.<\/p>\n<p>iii)\u00a0\u00a0\u00a0 Insure all quick links are secure.<\/p>\n<p>iv)\u00a0\u00a0 Wrap main chute in deployment bag.<\/p>\n<p>v)\u00a0\u00a0\u00a0 Insert main bag\/chute into payload compartment.<\/p>\n<h4><strong>d)\u00a0 <\/strong><strong>Connect nose cone to main chute payload bay<\/strong><strong><\/strong><\/h4>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Insert the nose cone into the main chute payload bay and align holes.<\/p>\n<p>ii)\u00a0\u00a0\u00a0\u00a0 Insert shear pins into holes and confirm a secure fit.<\/p>\n<h3>5)\u00a0\u00a0\u00a0 Motor Installation<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Assemble motor per manufacturer instructions.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Install motor in motor mount and verify snug fit of motor casing in motor mount tube. Tape motor casing for snug fit if needed.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Install Aeropack threaded retaining ring into motor retainer body.<\/p>\n<p>d)\u00a0\u00a0\u00a0 Tape igniter to airframe away from motor nozzle. \u00a0DO NOT install igniter until rocket is secure on the pad.<\/p>\n<h2>Final Launch Preparations<\/h2>\n<h3>1)\u00a0\u00a0\u00a0 Load Rocket on Pad<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Prepare launch pad.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Load rocket on launch rod.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Check tower&#8217;s position and be sure it is locked into place and ready for launch.<\/p>\n<h3>2)\u00a0\u00a0\u00a0 Arm HCX main altimeter<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Turn on power to HCX.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Arm drogue and main ejection charges.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Confirm proper settings via audible beeps and visual LED blinking.<\/p>\n<p>d)\u00a0\u00a0\u00a0 Confirm continuity for both channels via audible beeps.<\/p>\n<h3>3)\u00a0\u00a0\u00a0 Arm HCX backup altimeter<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Turn on power.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Arm drogue and main ejection charges.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Confirm proper settings via audible beeps and visual LED blinking.<\/p>\n<p>d)\u00a0\u00a0\u00a0 Confirm continuity for both channels via audible beeps.<\/p>\n<h3>4)\u00a0\u00a0\u00a0 Prepare Igniter<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Assure that launcher is not hot. Disconnect battery from relay box. Assure that key IS NOT in the remote device and that arming switch is off.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Be sure all connectors are clean.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Strike the igniter leads together to check for a spark<\/p>\n<p>d)\u00a0\u00a0\u00a0 Hook up the igniter outside the motor and check continuity<\/p>\n<p>e)\u00a0\u00a0\u00a0 Disconnect the igniter leads<\/p>\n<p>f)\u00a0\u00a0\u00a0\u00a0 Arm electronics<\/p>\n<p>g)\u00a0\u00a0\u00a0 Insert igniter. Be sure it is completely forward and touching fuel grain.<\/p>\n<p>h)\u00a0\u00a0\u00a0 Attach leads\/clips<\/p>\n<p>i)\u00a0\u00a0\u00a0\u00a0\u00a0 Back everyone away and perform final continuity check.<\/p>\n<p>j)\u00a0\u00a0\u00a0\u00a0 Hook up igniter to leads OUTSIDE OF ROCKET.<\/p>\n<p>k)\u00a0\u00a0\u00a0 Be sure leads don&#8217;t touch each other or that circuit is not grounded by contact with metal parts.<\/p>\n<p>l)\u00a0\u00a0\u00a0\u00a0\u00a0 Secure igniter in position.<\/p>\n<p>m)\u00a0\u00a0 Connect battery to relay box (if applicable).<\/p>\n<h3>5)\u00a0\u00a0\u00a0 Final Launch Sequence<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Insure Flight Witnesses are in place and ready for launch.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Ensure one flight witness is a member of L3C committee.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Signal LCO &amp; RSO that rocket is ready for launch.<\/p>\n<h3>6)\u00a0\u00a0\u00a0 Misfire Procedures<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Safe all pyrotechnic to pre-launch mode.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Remove failed igniter.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Resume checklist at step<strong> 2<\/strong><\/p>\n<h2>\u00a0Post-Recovery Checklist<\/h2>\n<p>This is the post-flight checklist as required as part of the Certification Package. This checklist includes steps required to ensure the rocket is in a safe condition after completion of a flight.<\/p>\n<h3>1)\u00a0\u00a0\u00a0 Post Flight Recovery \u2013 Successful Flight<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Safe all ejection circuits.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Check for non-discharged pyrotechnics.<\/p>\n<p>c)\u00a0\u00a0\u00a0\u00a0 Remove any non-discharged pyrotechnics.<\/p>\n<p>d)\u00a0\u00a0\u00a0 Have certification team fill out post flight checklist.<\/p>\n<p>e)\u00a0\u00a0\u00a0 Have certification team fill out L3 Certification affidavit.<\/p>\n<p>f)\u00a0\u00a0\u00a0\u00a0 Rejoice.<\/p>\n<p>g)\u00a0\u00a0\u00a0 Go buy more M motors and fly again.<\/p>\n<h3>2)\u00a0\u00a0\u00a0 Post Flight Recovery \u2013 Failed Flight<\/h3>\n<p>a)\u00a0\u00a0\u00a0 Follow Normal Post Flight Recovery procedures 1 &#8211; 3.<\/p>\n<p>b)\u00a0\u00a0\u00a0 Have certification team member fill out L3 Certification Failure Form.<\/p>\n<h1>4)\u00a0 \u00a0Appendix D &#8211; Recovery Electronics Flight Tests<\/h1>\n<p>Both the HCX units have been flown and successfully deployed their recovery devices prior to the certification flight.\u00a0 Each unit has been flown at least two times without incident.<\/p>\n<p>Power supply: 9volt battery<\/p>\n<p>Arming device: battery connector<\/p>\n<table border=\"1\" cellspacing=\"0\" cellpadding=\"0\" width=\"690\">\n<tbody>\n<tr>\n<td width=\"89\" valign=\"top\">\n<p align=\"center\"><strong>Altimeter<\/strong><\/p>\n<\/td>\n<td width=\"146\" valign=\"top\">\n<p align=\"center\"><strong>Most Recent Flight<\/strong><\/p>\n<\/td>\n<td width=\"96\" valign=\"top\">\n<p align=\"center\"><strong>Rocket<\/strong><\/p>\n<\/td>\n<td width=\"84\" valign=\"top\">\n<p align=\"center\"><strong>Altitude<\/strong><\/p>\n<\/td>\n<td width=\"108\" valign=\"top\">\n<p align=\"center\"><strong>Motor<\/strong><\/p>\n<\/td>\n<td width=\"84\" valign=\"top\">\n<p align=\"center\"><strong>Drogue Deploy Setting<\/strong><\/p>\n<\/td>\n<td width=\"84\" valign=\"top\">\n<p align=\"center\"><strong>Main<\/strong><strong> Deploy<\/strong><\/p>\n<p align=\"center\"><strong>Setting<\/strong><\/p>\n<\/td>\n<\/tr>\n<tr>\n<td width=\"89\" valign=\"top\">HCX1 (main)<\/p>\n<p>\u00a0<\/td>\n<td width=\"146\" valign=\"top\">4\/2\/2008<\/td>\n<td width=\"96\" valign=\"top\">Estes Patriot<\/td>\n<td width=\"84\" valign=\"top\">721 ft<\/td>\n<td width=\"108\" valign=\"top\">Estes E9-8<\/td>\n<td width=\"84\" valign=\"top\">Apogee<\/td>\n<td width=\"84\" valign=\"top\">500ft<\/td>\n<\/tr>\n<tr>\n<td width=\"89\" valign=\"top\">HCX2 (backup)<\/p>\n<p>\u00a0<\/td>\n<td width=\"146\" valign=\"top\">4\/2\/2008<\/td>\n<td width=\"96\" valign=\"top\">Estes Patriot<\/td>\n<td width=\"84\" valign=\"top\">420 ft<\/td>\n<td width=\"108\" valign=\"top\">Estes E9-8<\/td>\n<td width=\"84\" valign=\"top\">Apogee<\/td>\n<td width=\"84\" valign=\"top\">&#8211;<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n","protected":false},"excerpt":{"rendered":"<p>Polecat Aerospace Thumper \u201cAirborne Chris Craft\u201d Level 3 Construction and Recovery Package \u00a0 \u00a0 by David Randall NAR #84939 \u2013 L2 May 10th, 2008 Introduction This document comprises the construction package and recovery package for my NAR level 3 certification project.\u00a0 For my level 3 certification attempt I will be constructing a Polecat Aerospace Thumper [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":196,"menu_order":0,"comment_status":"open","ping_status":"open","template":"","meta":{"ngg_post_thumbnail":0},"_links":{"self":[{"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/pages\/1260"}],"collection":[{"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=1260"}],"version-history":[{"count":3,"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/pages\/1260\/revisions"}],"predecessor-version":[{"id":1414,"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/pages\/1260\/revisions\/1414"}],"up":[{"embeddable":true,"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=\/wp\/v2\/pages\/196"}],"wp:attachment":[{"href":"https:\/\/northwestrocketry.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=1260"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}