Wow, my first thread!

I recently ordered a Dr Zooch Saturn V, and before it comes through in the post, thought I would start this thread so I can get on and build it as soon as it arrives!
Although it is already a great kit, I would like to make it even more impressive by making it a cluster (this is only my third rocket, and first cluster, so i am a relative novice

). I was originally thinking of doing a 4 18mm cluster, but that would obviously not fit inside the body tube. I then thought that a better option would be to have one central 18mm engine, and then four outer 13.5mm canted ones (if that will even fit, which I doubt it will :s), so I could then fly it on either one, or a cluster of engines.
The problems that I am faced with are as follows:
1) What is the diameter of the body tube, and what arrangement of engines would fit inside it (see attachments for my ideas)?
2) I would like to keep the F1 engines attached during the flight, but do not know if this will be possible (see attachment for my idea).
3) As I do not have the Rocksim file of the Saturn V, I am not sure how much more weight I would need to add to the nose cone for it to be stable.
I am sure that these are only the start of my worries, and that I am going to have a difficult time trying to achieve my goal, but I know there there are some very talented rocketeers on this forum, and any input would be most welcome.
Thanks,
Silverfish
Here's what I know:
1) the kit is based on a BT-60 body tube, 1.637 inches outer diameter (check Semroc's site for the inner diameter, but I think you'll find your limited to a cluster of (5) 13mm mini-engines (dash-T engines) for this size body tube.
2) there is NO room to cant the engines, and NO reason to do so, because if you have one engine not ignite at takeoff, the off-axis thrust is DEFINITELY going to cause problems, making the rocket unstable. You can have enough problems as it is with the off-center thrust from a no-start as it is, with all the engines firing along the same axis-- with canted motors it's virtually certain doom.
3) this idea has been discussed before, and some folks have done it (search for the thread either here on TRF, over at Ye Olde Rocketry Forum, or on Rocketry Planet, I cannot recall at the moment which forum the thread discussing the cluster kitbash was on, but there is a lot of good information there.
4) One big problem you're going to have is, finding a long enough delay. Basically you're talking about launching a rocket with power equivalent to a "C" motor yet only having 2-3 second delay AT MOST, which is really too short for this model. The additional noseweight required will help offset this some, but you really need to model this in Rocksim to avoid nasty surprises...
5) The easy answer to the question of "how much noseweight" is, whatever the difference is in the weight of the new motor mount plus engines compared to the old motor mount with it's engine. Say you construct the kit motor mount per the instructions, install an engine, and it weighs (just a number here) 50 grams. Say you also construct your new clustered motor mount, install all the engines, and weigh it and it weighs in at say 150 grams. You'd have to install 100 grams of noseweight to offset the additional weight in the tail of the rocket, to keep the CG at the exact same point (negating moment-arm effects for the moment and assuming the CG is at the exact center lengthwise of the kit.) If the CG is further aft, less weight would actually be required in this case to move the CG forward, because that weight would be further from the CG (presuming you put it in the forwardmost part of the nose, which is NOT going to be easy with this kit since it has a BT-50 nosecone, already pre-weighted, and the rest of the cone is solid balsa, except for the paper Apollo Capsule through which the LES escape rocket dowel is glued. It would probably be possible to add plenty of weight to the BT-50 upperstage tube (representing the S-IVB stage) but the further back from the nose the weight is, the shorter it's moment arm and therefore the more weight is required to get the same forward shift of the CG. If you want, I could load and weight my Saturn V and locate the CG for you if built "stock" and that would give you reference to work from. That way, you install your cluster motor mount, and just add weight to the BT-50 tube until it balances at the exact same CG point as the unmodified kit.
6)This raises another problem-- as the weight of the rocket increases, so does it's inertial moments... meaning that the fins are less effective at stopping undesired motions of the rocket and take longer to push the rocket back onto the desired course (remember Newton's laws and conservation of momentum-- it's easier to get a lighter object moving than a heavy one, and it's easier to stop a lighter object when you've moved it far enough than it is to stop a heavy one. Your fins are the same size, so the amount of 'work' they can provide (lift when at an angle of attack) is the same, but now they're having to push a much heavier rocket back on course, which will take longer to accomplish. What all this means is the rocket is going to do a LOT of tailwagging and corkscrewing as it flies because it's underdamped, and just kinda 'flail around the sky' so to speak... Larger fins would help with this, but then they'll look funny too, unless you go with clear slip-on fins or add oversize clear fins to the back somehow (this will reduce the need for lots of extra noseweight as well, since extra-size fins will shift the CP rearward, meaning the CG doesn't have to be as far forward to maintain stability as it has to be on the stock kit with the stock fins).
7) You'll have to have a bigger chute to safely return this rocket from apogee, as hopefully that's where it'll eject, because of the additional weight. Rocksim would help here as well as it can calculate chute size for you and you can experiment with different size chutes until you get what you want.
8) It won't be possible to fly the rocket with the F-1 engines on the kit-- they're too small (see my build thread for more info on the Zooch Saturn V kit from a couple weeks ago). If you've clustered to 13 mm engines anyway, you COULD just extend the motor mounts out a bit (sorta like the engine 'spoofs' on the Zooch Atlas-Agena kit I've got a thread going on) and let them 'serve duty' as the F-1's. Don't move the engines too far back or you make problem #5 and 6 worse though... :shock:
9) since your just getting started good in rocketry, and haven't gotten any cluster experience before, I personally would recommend you file this project away for awhile. I know, I've been there too, and it's easy to get 'go fever' and want to jump into an uber-cool sounding project with both feet and realize later that you bit off more than you can chew, or that it just doesn't work, is dangerous, or whatever. If you're really determined to do this, I'd recommend that you get a commercially available clustered kit and build it stock-- it's amazing how much you can learn from each build if you pay attention to what you're doing and WHY you're doing it that way, what the reasoning is and the mechanics behind it, and then you can figure out better ways of doing it later on

Seriously, some familiarity with commercial designs will help to know what works and what don't, what to look for, etc. before jumping into a project like this.
10) If ya don't have rocksim, you're really missing out. Rocksim is PERFECT for a project like this because it helps you SO MUCH to see how things fit together before you actually build it, to test things out, see what works and what doesn't, etc. You have to be careful with Rocksim, because as most computer guys will tell you, "junk in-junk out", meaning the simulations and stuff are ONLY AS GOOD AS THE INFORMATION YOU PUT IN-- the more accurate, the better! Actually weigh the components you're contemplating and plug those numbers into the design instead of the 'default' numbers (not that the defaults are all bad or anything, but the more accuracy you have in the component weights, the better the CG calculations will be, the better the sim runs will be, etc.) I'd even recommend that if you go forward with this, that you build a 'boilerplate' version of it from paper towel tubes (they're usually BT-60) and test the idea out using cheap parts before you build the real thing-- that way if it crashes, you're only out the paper towel tube and not a kit...
Good luck and any more questions feel free to ask! OL JR
