Boris Katan flights 2017 -> Clusters + 3D Printing Fun <-

Discussion in 'High Power Rocketry (HPR)' started by delta22, Mar 5, 2017.

  1. Mar 5, 2017 #1

    delta22

    delta22

    delta22

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    For 2017 will post all my projects and flights in one annual thread as in previous years.
    This makes is easier for me to post, and easier to follow for anyone who subscribes.
    Also avoids having threads for some projects and not others.

    My Winter goal is to prep for LDRS April 6-9.
    Looking forward to flying at MDRA for the first time.

    Planning three pairs of flights: speed, spinning and clustered+staged.

    Speed:
    Carbon Weasel on CTI J530 Imax. 38mm minimum diameter 16oz rocket, should do Mach 2+
    Carbon fiber body tube with LOC Weasel NC and fins. Previously flown 3 times Mach 1.5+

    SkyHook 2 on CTI K1440 White Thunder. 54mm minimum diameter / flying case. Build in progress.
    Goal is for the rocket to add <1.5lbs to the 4.1lb motor and break Mach 2.5. Bonus points for breaking 2000mph :dark:

    Spin - a couple seasoned fliers:
    Turbine Rocket Saucer on 6x D11-P
    Spinning Saucer of the Apocalypse on 8x D11-P + 2x G - maybe skids??

    Clustered and staged:
    Nitro Fireball 7ft x 4in first stage on a cluster of 7x 29mm + 16x 24mm.
    Second stage 6x smaller rockets – FlisKits ShadowLords on D12 engines
    Has flown in a modified version of this setup 4x previously.

    HellBoy 2 staged 70 motor flight. Repeat of a flight done successfully in 2012.
    stage 1: 51x C11 to stage 2: 19x D11-P :surprised:
    pic 1: stage 1 motor pack bonded with fast epoxy
    pic 2: motor pack and inter-stage bits

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  2. Mar 5, 2017 #2

    delta22

    delta22

    delta22

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    Stage 2 of the Nitro FireBall:

    pic 1 and 2: 6x cool FlisKits ShadowLord kits

    pic3 and 4: ShadowLords, a (black) fin guide I designed and 3D printed, plus the assembled HellBoy stage 1 (minus fins)

    pic 5: hardened balsa NCs and fins with slow epoxy thinned with alcohol

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  3. Mar 5, 2017 #3

    delta22

    delta22

    delta22

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    For the SkyHook 2 54mm speed project:

    pic 1: 3D printed several test rings, varying size 0.1mm to get ideal fit for NC shoulder, before printing the shoulder itself

    pic 2: using thin wall FG nose cone, cut out hole for keychain video camera mount. 3D printed NC shoulder and alt bay sled - located in NC. Chemically welded sled and shoulder with a slurry of acetone and ABS.

    pic 3: the very lovely carbon fiber over Nomex honeycomb fins. Custom made by Robert at AMW.

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  4. Mar 5, 2017 #4

    delta22

    delta22

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    Stage 1 of the Nitro FireBall staged cluster:

    pic 1: 7x 29mm starting point

    pic 2: more motor tubes. :facepalm: 24mm LOC cardboard tubes covered with thin fiberglass and black tinted epoxy.

    pic 3: some of those motor tubes plus 4in x 1/8in basswood

    pic 4: wrapped in more thin FG and black tinted epoxy

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    Last edited: Mar 5, 2017
  5. Mar 5, 2017 #5

    delta22

    delta22

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    Had to repair / upgrade my SeeMeCNC RostockMax 3D printer over the winter.

    Tried to tighten the plastic travelers that are moved up and down the rail by the toothed belt. These in turn move the upper part of the arms that move the print head.

    Found that after a year of use, there were many fractures in the plastic. Replaced them with the very nice (pictured) aluminum traveler and pulley assemblies from TrickLaser.

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    Last edited: Mar 5, 2017
  6. Mar 5, 2017 #6

    AeroAggie

    AeroAggie

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    Uh, WOW. Guess I'll stay tuned....:surprised:
     
  7. Mar 5, 2017 #7

    neil_w

    neil_w

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    Now I'm even more bummed I can't make it to LDRS. :( Oh well, I'll just look forward to the reports in this thread....
     
  8. Mar 5, 2017 #8

    KennB

    KennB

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    There's a man who's made good use of his winter.
    Boris, save something for the home fields or just fly more and more.
     
  9. Mar 5, 2017 #9

    dhbarr

    dhbarr

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    :popcorn:
     
  10. Mar 5, 2017 #10

    rstaff3

    rstaff3

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    Darned good start to your 2017 thread!
     
  11. Mar 5, 2017 #11

    BDB

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    How do you invite the sustainer for these huge cluster 2-stage rockets? Is there going to be a mid-flight BP flashpan?
     
  12. Mar 5, 2017 #12

    delta22

    delta22

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    For the HellBoy two-stage flight, there will be a flashpan for each stage.
    First stage triggered by LCO, second stage fired one second later by the same Raven that triggers the ejection charges.
    Second stage will only fire at one second if first stage launch has achieved a minimum level of accelerometer calculated speed, assuring that there will be no second stage ignition if the first stage fails to get the rocket off to a fast start.

    For the Nitro FireBall, there will be a flashpan for the central cluster of first-stage BP motors only.
    The 6x small second stage rockets each are powered by one D12. These will be fired by C11-0 first stage motors, located in the black tubes pictured above in the fin ring. Those first stage C11's will each have their own igniter, as they are 4+ inches away from any other first stage motors.

    This is different from previous Nitro FireBall flights, which had used electronic ignition for the 6x second stage rockets. This proved to be unreliable and a huge PITA to set up.

    Pictures of previous flights on the website in my signature and past TRF threads.
     
  13. Mar 5, 2017 #13

    rstaff3

    rstaff3

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    If there is any way to guesstimate which day the Hellboy will go up please let us know. I'm going visit LDRS for one day and would like to see it if possible. I know it's hard to plan firmly and on-site plans can change (heck I might not be able to make it that day). But any guess is better than none. TIA!
     
  14. Mar 5, 2017 #14

    delta22

    delta22

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    Tentatively planning speed flights for Thursday, spinners for Friday, and clusters for Saturday.
    Very dependent on weather.

    Traveling home Sunday. That one is more firm, as I am dependent on working Monday ;)
     
  15. Mar 5, 2017 #15

    rstaff3

    rstaff3

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    Thanks, Saturday is likely the day I will go over to watch. Weather is a big wild card.
     
  16. Mar 5, 2017 #16

    kramer714

    kramer714

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    I thought my cluster was big, gotta get a good video of the midair on yours. Very cool
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  17. Mar 5, 2017 #17

    MALBAR 70

    MALBAR 70

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    Boris's cluster flights are legendary. Check out the link at the bottom of his sig. There's some awesome stuff there.
     
  18. Mar 6, 2017 #18

    NateLowrie

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    Boris, this looks awesome. I got the parking spot next to you for LDRS. If you need help getting things into the air just stop on by. We'll be there Thursday-Saturday.
     
  19. Mar 7, 2017 #19

    delta22

    delta22

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    Thanks all for the kind words.

    Mike and Nate, LDRS will be a whole lot of fun, looking forward to being neighbors.

    Nate, I'll gladly accept any available help setting up my cluster flights, tentatively planned for Saturday.
     
  20. Mar 7, 2017 #20

    delta22

    delta22

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    pic 1: Put a drop of thin slow epoxy under each capacitor on 2 new Ravens. Helps them hold up to high Gs. The Carbon Weasel hit a max of 84 Gs on an I 540 in a previous flight.

    pic 2: Started adding more 24mm motor tubes to the central cluster, because - hey more motors :wink:

    pic 3: Sanded and then coated with thinned and pigmented epoxy to (fire and surface) harden the ring fin

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