'Fin & Sonic' - An NZRA L1 / L2 certification rocket - MAC Performance Rocketry: Hyper 54 - X Rated Phenolic

[spigalau]

With the departure of my rocket buddy (& son) to the Southern Island for his studies, my daughter has decided to pick up the mantle.

After several years of screen drooling, the kit we have opted for is one of Mikes - Hyper 54 kits using his new XX Phenolic material.
When we inquired with Mike about availability & delivery (I wanted to pick it up whilst visiting CA) he gave us an option of trying the new material, so we went with it.

The rocket is called 'Fin & Sonic' which is a homage to mum's favorite tipple, the speeds that we can expect to see this hit and a little blue hedge hog.

The initial impressions of this kit on unpacking it, was OMG... the fit is spot on, you could almost fly this out of the box. The only epoxying to do is Nose Cone to Collar, Switch Band to Coupler & Motor Retainer to booster.

Out of the box, she fits together like Lego, this is the kit assembled without any bonding, talk about a friction fit.



First up, we prepped the Switch band for attachment - tube was give a rough up with 80 grit and cross hatch scour


The the nose cone / collar was given the same treatment, as was the bottom of the booster section (for the retainer - not pictured)


After cleaning the surfaces with acetone, the two were glued using JB Weld.




Being a min diameter 54mm doesn't leave much room on the AV bulkheads, but it's now fitted with 2 x 2.5g charge wells (top & bottom) for the redundant charges.

Due to space constraints, it's going to fly on a single Altus Metrum Telemega 6 with events configured as Apogee, Backup Apogee +2 seconds, Main @ 1,000', Back Up Main at 850'.
The charge wells & eye bolts have been thread locked with loctite 263 stud lock.




Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
3) Vent Holes
4) Shear Pin Holes
5) Painting
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing

And yes - NZRA (New Zealand Rocketry Association) does allow the use of the alloy fin can for L1/L2 certification flights.

Attached is Open Rocket SIM file for this build - flying on 54mm I's (L1) - we should expect something between 4,000 to 6,000 feet
For L2, the simulations are indicating that J's are 7,000 to 11,500', K's are 11,250' to 21,000' & L's are 20,700' to 29,000' @ Mach 2.61

Aim is to fly at the May members day (May 7) and get her L1 done before our winter shut (damn cows), with an L2 attempt in Q4.

 

[3stoogesrocketry]

Very cool build. Mike sure does great work. Those charge canisters seem excessively big though? I cannot imagine you will need much more then a 1/2 to 3/4 of a gram.

 

[g.pitts]

Glad that she's interested in rocketry and is keeping the family hobby going strong! The kit looks solid, and I really like your charge wells. Your build velocity runs circles around mine!

 

[spigalau]

Retention of Payload tube to AV Coupler now complete.

2 x Torx T20 screws locating in to embedded nuts on the inside of the airframe.
Nut's retained with ' Selleys Knead It' - an easy to use epoxy (refer: https://www.selleys.co.nz/products/adhesives/minor-repairs/selleys-knead-it-multipurpose/) .

Front side:


Back Side:


And with the Torx T20 in place, no OCD person can ever complain about the screws not being aligned to the air frame.


We then moved on to the keying of the booster & payload tubes.

Hole's drilled & cleaned before pegging.


Post Pegging:




The pegs will need to be sanded back / shaped down, so added a 2.5) to the list to do below.

Now that it's been keyed - we can drill the shear pin holes (2 x M3 for Booster, 2 x M3 for Payload) and can be sure that the pins will always be in the right place.

So the mid / upper air-frame now looks like:


Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing

 

[OzHybrid]

Retention of Payload tube to AV Coupler now complete.

2 x Torx T20 screws locating in to embedded nuts on the inside of the airframe.
Nut's retained with ' Selleys Knead It' - an easy to use epoxy (refer: https://www.selleys.co.nz/products/adhesives/minor-repairs/selleys-knead-it-multipurpose/) .

Front side:
View attachment 572498

Back Side:
View attachment 572499

And with the Torx T20 in place, no OCD person can ever complain about the screws not being aligned to the air frame.
View attachment 572504

We then moved on to the keying of the booster & payload tubes.

Hole's drilled & cleaned before pegging.
View attachment 572500

Post Pegging:
View attachment 572501


View attachment 572502
The pegs will need to be sanded back / shaped down, so added a 2.5) to the list to do below.

Now that it's been keyed - we can drill the shear pin holes (2 x M3 for Booster, 2 x M3 for Payload) and can be sure that the pins will always be in the right place.

So the mid / upper air-frame now looks like:
View attachment 572503

Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing

Change SECURITY Torx screw for something you can find more readily. Even if you have a Torx T20 security bit, if you lose it at the field you'll make life more difficult for yourself than it needs to be. Unless there is a specific, unavoidable reason to use a non standard screw, don't do it.....
Norm

 

[spigalau]

Change SECURITY Torx screw for something you can find more readily. Even if you have a Torx T20 security bit, if you lose it at the field you'll make life more difficult for yourself than it needs to be. Unless there is a specific, unavoidable reason to use a non standard screw, don't do it.....
Norm

Hi Norm - I have a bag of 100 of the sods, cost all of £1.31 (Rapid Electronics)
Also got a couple of T20 screwdrivers in the rocket support toolkit so no bits to loose

The specific reason for having them was to avoid my son's OCD about things not being straight.

 

[spigalau]

Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing

 

[spigalau]

Nose Cone Shear pins - 2 x M3 Nylon
Payload Vents 4 x 3mm


AV Section - 3 x 3mm Static Ports with 2 x M3 Shear pins on lower for booster


Booster Vents 4 x 4mm - located about 4" about where an L1000 would end at.



Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
6.5) Create 3D model for battery holder & 2Mag switch for rear of AV board
6.75) Print it
7) Fin Canning
8) Motor Retainer
9) Ground Testing

We have enough white one shot undercoat acrylic to start the painting of the nose, hopefully can get a couple of layers on with the airbrush before it runs out. No idea why, but only able to find 2 other bottles of it in NZ - so ordered it and it's on it's way. Hopefully get's to here on Thursday before our long weekend.

 

[spigalau]

Started the painting process with the little bit of One Shot primer we had left.

Before:


After 1 coat:


After 2 coats:


And enough to do a single shot on the Payload.


I'm surprised how economical the airbrush was on the coverage - wouldn't have been 15mls left in the container to start with.

Hopefully paint supplies arrive tomorrow to carry on.

Aiming to give them 3 hits of primer, sand it back with some 1200 grit and then lay down the colour.

 

[spigalau]

First coats applied.



Body Tubes are AMMO Metallic Red - AMIGO188
Nose Cone is AMMO Warhead Metallic Blue - AMIGO196

Still quite light due to white under coat, will darken up after second coat.

 

[spigalau]

And after 3 coats - now ready for clear coat.

Wifes car aerial makes a good holder for drying nose cone.


Payload Tube has a glint:



Improvised drying area - 2 x Warratah's (3 sided metal post) in a drain grate:


Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.3) Clear Coat
5.5) Order Decals !
6) Electronics
6.5) Create 3D model for battery holder & 2Mag switch for rear of AV board
6.75) Print it
7) Fin Canning
8) Motor Retainer
9) Ground Testing

 

[spigalau]

Fastback Motor retainer JB Welded in place - fin can now ready for locking down


Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.3) Clear Coat
5.5) Order Decals !

6) Electronics - Altus Metrum Telemega 6 sent away for SMA antenna conversion (3.25" TM + 2" stubby = 5.25" consumed of 7" space)
AV back plate (front side) has pegs applied so can just mount it when it comes back. Nylon stand offs initially attached with 5 min epoxy and then additional re-enforcement with an epoxy putty.


6.5) Create 3D model for 1S battery holder & 2Mag switch for rear of AV board.
Simple box to be screwed / bolted to the back of the board. 2mag switch to be pegged to the lid of this once in place - added advantage that the 2mag will now be a lot closer to the air frame.


6.75) Print it

7) Fin Canning - Underway

8) Motor Retainer

9) Ground Testing

 

[spigalau]

Quickly running out of things to do... launch date May 8th.

3D Printed Battery box for the back of the AV board:


The 7" Altus Metrum Telemega 6 whip antenna is being replaced with:



So now plenty of room inside the 7" coupler to play with.

If @Ethan remembers to drop around a motor casing tonight - we should be able to attack the ejection charge testing tomorrow AM.

Still need to order the decals.. must do that.

Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing
10) Send it !

 

[spigalau]

Had to tuck the second set of battery wires out of the way.

Blue is faster - right ???

 

[spigalau]

Ground testing complete.



Next job/s are:
1) Retention of the payload tube with Torx T20 screws to coupler.
2) Keying of AV switch band to booster tube.
2.5) Sand / Shape the excess pegs from the Keying
3) Vent Holes
4) Shear Pin Holes
5) Painting (04/03/2023 - Paint Ordered)
5.5) Order Decals !
6) Electronics
7) Fin Canning
8) Motor Retainer
9) Ground Testing
10) Program Electronics !
11) Send it !

Yeah must order the decals too... we have been a bit slack on that one.

 

[spigalau]

Modified TeleMega 6 now fitted.

 

[spigalau]

Decaled - ready for flight attempt tomorrow (pending weather gods).





I271 simming to 5250'

 

[spigalau]

Before....

 

[g.pitts]

Before....

View attachment 579268

Good luck with the launch!

 

[spigalau]

Success - Flight video to follow.

To clarify: 1S = Under 18, so supervised by an adult.

 

[Handeman]

Congrats!!!!

 

[bad_idea]

Congratulations!

 

[kjhambrick]

Nice documentation of the build.

Well done !

Congrats !

-- kjh

 

[spigalau]

Flight #1

 

[g.pitts]

Bravo, Megan! Nicely done.

 

[Hobie1dog]

Thanks for all the pictures and video

 

[spigalau]

So for her flight #2 she was being sent skywards on a VTP J522 Supernova - expected altitude of ~9000' & a speed of Mach 1.07

On the pad, she looked the business.



Alas, shortly after ignition, the forward closure decided to part ways with the motor casing:

Looks like the circlip was not fully bedded, which allowed it to round out the case and vent gas to the booster tube.
Note: JB welded motor retainer also shifted south by 5mm.

Fly away rail guides bore the brunt of the departing gases - lower pair & spring are well shagged. Upper pair & rods appear to be OK-ish.



The Max-Q Fin can has been retrieved from the lower section of the booster tube, and now needs a new home for it.


As it's now our 'no fly / winter' period - will look at a couple of different ways of resolving the breakage.
Existing booster was 42" long, MAC can supply up to 59" XX Phenolic @ 54mm now... only killer cost will be shipment to NZ.
Shagged booster, may now become extended payload tube

L2 attempt will be in October now... she's thinking L1000 - just for ***** & giggles.

 

[Hobie1dog]

So for her flight #2 she was being sent skywards on a VTP J522 Supernova - expected altitude of ~9000' & a speed of Mach 1.07

On the pad, she looked the busin

Alas, shortly after ignition, the forward closure decided to part ways with the motor casing:

Looks like the circlip was not fully bedded, which allowed it to round out the case and vent gas to the booster tube.
Note: JB welded motor retainer also shifted south by 5mm.

Fly away rail guides bore the brunt of the departing gases - lower pair & spring are well shagged. Upper pair & rods appear to be OK-ish.

View attachment 586063

The Max-Q Fin can has been retrieved from the lower section of the booster tube, and now needs a new home for it.


L2 attempt will be in October now... she's thinking L1000 - just for ***** & giggles.

OHHHH NOOOO

 

[spigalau]

28/06 - Ordered replacement 54" booster tube, should be in country mid next month.

 

[OzHybrid]

So for her flight #2 she was being sent skywards on a VTP J522 Supernova - expected altitude of ~9000' & a speed of Mach 1.07

On the pad, she looked the business.

View attachment 586058

Alas, shortly after ignition, the forward closure decided to part ways with the motor casing:
View attachment 586059
Looks like the circlip was not fully bedded, which allowed it to round out the case and vent gas to the booster tube.
Note: JB welded motor retainer also shifted south by 5mm.

Fly away rail guides bore the brunt of the departing gases - lower pair & spring are well shagged. Upper pair & rods appear to be OK-ish.

View attachment 586063

The Max-Q Fin can has been retrieved from the lower section of the booster tube, and now needs a new home for it.
View attachment 586062

As it's now our 'no fly / winter' period - will look at a couple of different ways of resolving the breakage.
Existing booster was 42" long, MAC can supply up to 59" XX Phenolic @ 54mm now... only killer cost will be shipment to NZ.
Shagged booster, may now become extended payload tube

L2 attempt will be in October now... she's thinking L1000 - just for ***** & giggles.

Good luck with the next attempt. Nice fin can. I've got one similar. Good choice.
Looks like 2.125" tube (54mm) is readily available. You could buy a bit and lay up your own fiberglass tubing on it. It's pretty easy to do.
https://www.cobyexhausts.co.nz/product/736-54mm-mild-steel-tube-x-1-6mm-wall