I have to ship a 75mm minimum diameter rocket across the U.S. for an exhibition. I know that many of you ship your BALLS rockets to Black Rock every year, and I want to know if anyone can describe your methods to ensure that it arrives undamaged? Having had multiple fiberglass components from vendors over the years arrive damaged after shipping, I want to be as safe as possible.
I'm thinking about using a standard cardboard box with 2x4s in the corners to ensure that it doesn't get crushed, and packing peanuts and foam all around the rocket. Maybe additional 2x4's supporting the airframe and centering it in the box? Should I leave the electronics in the rocket, or take them out and pack them separately? What do you do to protect the fin can? Should I mark the box "Inert" in big black letters to highlight that there's no propellant inside if they x-ray it, or would that just attract more attention?
Wielder Of the Skillet Of Harsh Discipline, Potentate of Perilous Pans
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2x4s are overkill, and will just make it expensive.
I have a 4" rocket I shipped to PA for painting. I used firring strips to make a box frame which I then covered with cardboard. I cut a piece of 1" foam to make a plug for each end. One went in the "bottom" and cardboard folded over and it was taped shut. Then the rocket, suspended in settled packing peanuts, and then the other foam piece in the "top", fold cardboard, and tape.
I used a Kmart footlocker to ship from Minneapolis to Phoenix and back.
4 inch airframe plus on board camera, electronics and motor components.
Heavier then cardboard but will take substantial handling abuse without compromising the contents. Hinged and lockable lid more convenient and secure then tape on a box.
This was checked luggage on an airplane pre 911 days.
Here is what I did when I had to ship a rocket cross-country. It doesnt use 2x4s (you can definitely get away with something smaller), but is still similar to to your idea.
The bottom plywood plate unscrews and the slot near the nosecone base in the picture is where the nosecone U-bolt inserts and the cone is held tight against the hole in the center cut out. The 4" diameter body is held in place by the wood square on the bottom plate. There is a similar assembly on the top that holds the other side of the body tube. The entire wood assembly fits in a cardboard box. I put tape wherever the rocket contacts the wood so the paint doesn't get messed up.
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