Follow-up.
I've flown this rocket four times and have learned a lot along the way. Here is the rundown for those interested.
Flight #1 was the L900DM, and that motor was iffy at best--not recommended. I believe that Ti slag deposition on the nozzle causes 'vectored' thrust early in the flight. I've seen several Dark Matter flights exhibit the same unstable behavior. Not long after leaving the rail, the rocket left a vertical orientation (maybe 65 degrees 'up'), and experienced a high-speed apogee event. A small part of the lower body was crushed by the kevlar recovery harness, which was small enough to ignore. Also, the nosecone failed to stay on after apogee despite three 2-56 nylon shear pins.
Flight #2 was an M1297 a year ago. Rocket went to 13.2k and over Mach 1. The nosecone again came off at apogee, and the main was not connected when fired out. My fault and I did not certify. I put together the rocket with a checklist the first time. At the launch site, more than a few well meaning people offered their 'advice' before the flight, which planted seeds of doubt in my mind. All told, I took the rocket back apart several time to 'check' things, leading me to miss reconnecting the main and nosecone.
I drilled out the 3 upper airframe to nosecone shear pin holes to 4-40, and added two static pressure ports in the upper airframe.
Flight #3 was a month ago on the AT L1390G. Rocket went to 11.1k and Mach 0.91. Nosecone stayed on until main charges went off! Nominal flight.
Flight #4 was two days ago on an AT M1780NT. Rocket went to 14.1k, pulled 24.7Gs and Mach 1.2! Nominal flight and L3 cert, finally! Picture below.
Raven File
View attachment JihadThis 20Mar15 M1780NT L3.FIPa
RRC3 File
View attachment JihadThis 21Mar15 M1780 L3.rff
Lessons learned:
1. The higher and faster you go, the more static pressure ports matter
2. Even a 4" rocket can benefit from 4-40 nylon shear pins
3. Stay away from AT Dark Matter with heavier rockets; stick to Metalstorm or another OEM's sparkies
4. Ignore good advice just before an L3 attempt from anyone but your TAP; stick to your checklist!
5. Tell yourself the L3 cert flight is 'just another flight'. It worked.