Stretch Stubby

Upon returning from being on the West Coast for July, Alice & I hustled a bit to get a new rocket of hers ready for the August PARA launch just a few days later:

Alice’s ASP Stretch Stubby.

It’s a Stretch Stubby kit from ASP that we received as a surprise gift in an order from a Fourth-of-July sale. It’s one member of a family of “Stubby” rockets from ASP, the other, shorter, ones being actually stubby. We were immediately intrigued to see that the rocket’s made up of several sections of tube, not one. That meant we could convert the kit just a bit so that it can be prepped and launched with any combination and ordering of the sections. Seeing how easy it’d be, I was actually a bit surprised the kit wasn’t designed explicitly to do so. In any event, having distinct sections like that would make it really easy for Alice to paint them in different colors. She was also very interested in being able to change the configuration before each flight. So she got to work on a sketch of her desired paint scheme and I made up a simulation model to evaluate the stability of different length configurations.

Alice’s design sketch.

Simulation in OpenRocket of full 4-segment Stretch Stubby.

Simulation in OpenRocket of minimal 1-segment Stretch Stubby.

Design & Construction

It turned out all of the configurations were projected to be stable without modification except for flying with solely the tail and nosecone. To add just a little challenge, shifting the center of gravity far enough ahead of the center of pressure in that minimal setup would require a lot of weight if added at the base of the nosecone—the weight would be practically right at the center of pressure given the minimal body length. The ballast had to go at the very tip of the nosecone, and ideally only in this configuration. So I swapped the gorgeous BT-60 MS balsa nosecone from the kit with a plastic one I had laying around. I cut the shoulder open and made a 3D printed screw-in compartment that could be epoxied into the tip. With more time I would have designed & printed a whole nosecone with an integral compartment, but we were on a tight schedule. That compartment provides a place to firmly secure varying weights right at the farthest forward point of the rocket. It also holds the weight in a fixed position rather than swinging about if it was just clipped to the line. The hollow nosecone also let the parachute be packed inside, shifting that weight forward as well. The compartment’s plug additionally serves as the tie down anchor for the shock cord. After unscrewing it and unhooking the parachute’s snap swivel attachment, the line passes easily through the tube sections for swapping them in and out.

After assembling the rocket together, Alice painted it precisely to her previously devised specifications. Her spray painting has improved quite visibly the past few months. Size and weight of the cans is still a challenge, even with a pistol grip attachment, but she’s gotten vastly better at not spraying the paint on too thickly in one go. This time she did though thoroughly entertain herself by “accidentally” heavily spray painting my hand purple while I was holding the nosecone for her. Periodically for days afterward she would randomly stop amid some other activity and ask “Daddy, why’s your hand purple??” and cackle wildly.

In the end, having constructed, finished, and weighed everything to update the simulation with real numbers, a 20g fishing weight tucked into the compartment was projected to make the minimal configuration satisfactorily stable.

Gluing the tube couplers into the body sections.

Covering a fin with sandable wood sealer so they can be smoothed out (full disclosure, this is a fin for another rocket we did a little work on at the same time but haven’t finished yet).

Nosecone ballast compartment, screw-in plug & shock cord mount, and parachute swivel snap.

The disassembled assembled rocket.

First Launch

Alice prepping her rocket. (photo by Mike S)

Notes on motors and configurations for prepping the rocket at the field.

Our first launch of the completed-just-in-time rocket was pretty successful. However, after that one just-slightly-creepy retrieval from deep in the corn, and rightly afraid of losing the rocket forever amid the field of 7+ foot tall stalks, Alice decided to call the day a success without trying out all configurations of the rocket. She says we’ll do that once the harvest is done…

Alice wading into the corn on a retrieval mission.

Stretch Stubby, I presume?

R2

Recently I finished R2, a scratchbuilt somewhat over-engineered BT60 sized 18mm model, and got in its first two flights at the April 2021 PARA launch. It came out pretty much exactly how I had envisioned, and wound up with a very satisfying second flight after a nearly catastrophic inaugural flight.

R2 finished (one side).

R2 finished (one side).

Construction

R2 began with modeling in OpenRocket, inspired by and based on a BT60 tube and nosecone from a ~26 year old Estes Designer’s box. The design has a payload compartment just for fun, through-the-wall papered fins that interlock with the motor mount rings, redundant Kevlar threads running from the motor mount to the shock cord, conformal angled launch lugs, and a couple other unnecessary touches. I just wanted to build a big, substantive feeling, low power rocket, and experiment with some construction techniques for strength and redundancy. I wasn’t too concerned about weight or overkill features for a rocket intended to fly on C motors at most. Slow, heavy-feeling flights would be just fine (provided stability was good & flights safe).

Modeling R2 in OpenRocket.

Modeling R2 in OpenRocket.

Other than the tubes, nosecone, and parachute, R2 was built up with a mix of 3D printed and CNC cut parts. The boattail was printed on a Wanhao i3+ in ABS for heat resistance, and the launch lugs the same for convenience. The tube coupler is in PLA printed on an Ender 3. Since the coupler isn’t exposed to significant direct heat I’m not too worried about the PLA, but in hindsight I wish I’d done it in ABS as well just to have no doubts about it sitting in a car trunk on a hot day. The fins, centering rings, and bulkheads were cut from 1/16″ balsa using a Cricut Maker. Strength was added by papering the fins with adhesive paper and coating the edges with CA. Rings and bulkheads were beefed up with a PVA glue coating.

Drawing the fin pattern in OpenSCAD.

Drawing the fin pattern in OpenSCAD.

3D printing the boattail.

3D printing the boattail.

All R2's pieces ready for assembly.

All R2’s pieces ready for assembly.

Marking the tube for the fin slots.

Marking the tube for the fin slots.

Gluing together a combo coupler and payload bay bulkhead.

Gluing together a combo coupler and payload bay bulkhead.

R2 fully assembled.

R2 fully assembled.

Finishing

Painting was done with Montana spray paints over a Rustoleum primer sanded down. The Montana paints go on kind of thick & heavy, they’re made for graffiti art, but because of that lend themselves to consistent, smooth, very opaque feeling finishes. The big “R2” lettering was done using vinyl stencils and spray paint while the other details are custom vinyl stickers. The stickers were printed on an inkjet and then they & the stencils cut out with the Cricut. The “SPACECRAFT” icon is a stock art logo I bought as tongue-in-cheek representation of a generic NASA/ESA/whatever. The US, Canadian, and Korean flags were chosen just because they look cool, it doesn’t reflect any actual mission partnership or such.

Really my only disappointments with the rocket came in finishing. One of the stickers on the nosecone smudged a bit in application. I also didn’t think enough about the striping on the payload bay, so there are 10 stripes instead of 8 and they don’t line up exactly with the quartered paint scheme of the body. But overall I think it came out well and looks real cool in the background on video calls.

R2 finished (other side).

R2 finished (other side).

R2 finished (nosecone detail).

R2 finished (nosecone detail).

First Flight—Disaster!

There isn’t anywhere immediately near home to fly anything larger than maybe a 1/2A, so the first R2 launch had to wait until the next PARA meet. I got a good slow motion video of the launch itself, there was a successful parachute ejection, but then disaster: It was a windy day and the rocket drifted into trees immediately behind us.

R2 on the launchpad for its debut.

R2 on the launchpad for its debut.

Ignition!

Ignition! Photo by Mike S.

Up in a tree!

Up in a tree!

Fortunately the club has a telescoping pole with which we were just barely able to reach the rocket. It took some finagling, but eventually we were able to get hands on the rocket. The shock cord stretched a ridiculous amount so it took some effort even beyond that point, but we were eventually able to rip the rocket down.

Getting out the rescue pole.

Getting out the rescue pole.

Hooking the line.

Hooking the line.

Pulling R2 off the tree.

Pulling R2 off the tree.

Second Flight—Success!

Initial damage assessment indicated the parachute was ripped in several places, one shroud line was still in the tree, and a bulkhead was gone. All in all R2 was in reasonable shape but I assumed I wouldn’t be able to fly it again that day. I kept looking at it as the day went on though and really wanted to get in another flight. So between helping Alice launch rockets and other goings-ons, I got to work. The parachute got more or less taped up, lines replaced and retied, the remaining bulkhead reinforced, and so on. It all came together at literally the end of the meet as people started talking about packing up the launch pads. With the very last launch of the day, R2 pulled off a picturesque second flight, up to 365 feet and almost back to my hands.

Staged for second launch.

Staged for second launch.

Wrap

R2 came out great. It looks exactly as I wished, it was a fun build, and it had a perfect second flight with just enough drama beforehand to accentuate the success. I don’t know how much more I’ll fly it and risk R2 getting captured for good by those hungry trees! But it flew well, looks real nice in my office, and was a good little project.

R1

R1 and Alice’s Estes Zinger.

After having it built for a month, we finally flew R1, the first rocket I’ve designed in ~30 years. I had put this together overnight as a backup rocket in case something happened to Alice’s Estes Zinger at her first launch, but we did not wind up flying R1 then. Yesterday’s PARA520 launch presented an opportunity though and it had a great debut flight, sailing straight up and then… drifting into an intensely muddy but fortunately empty cow pen. Ok, that last part could have been better, but at least the clean paint job did not get particularly dirty.

R1 modeling in OpenRocket.

R1 is a very basic rocket largely made out of parts from an old Estes Designer’s Special box. Although no doubt overkill for such a straightforward rocket, it was modeled in OpenRocket in order to adjust the sizing and hit a good stability caliber. It has a balsa nose cone, BT20 tube, and four trapezoidal fins. These were cut by hand from 1/6″ balsa but I made a mistake and oriented the grain weakly, which I only realized when they snapped in transport. So I cut sticker paper for both sides of each fin and glued the leading edges, so now they look sharp and are very strong. Recovery system is a small parachute and it launches on 1/8″ rod. The finish is simple spray painting that was literally still drying in the car on the way to our January launch… The purple body came out particularly rich and smooth though despite the hasty work.

On the launchpad at PARA, March 7.

On the launchpad w/ Alice’s orange starter rocket.

In the end I’m very pleased with this simple rocket. Clean looks, strong, flew well. Can’t ask for much more for a last minute, late night scratchbuild.