# Thales Starstreak build

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#### BrendanH69

##### Well-Known Member
TRF Supporter
Thanks mate! I'm sure I'm over-engineering it a bit, but good to know it might help you too, Drew. If it wasn't for your spark and kick-start with this idea, I wouldn't have been inspired to run with this!

#### DrewW

##### Well-Known Member
Thanks mate! I'm sure I'm over-engineering it a bit, but good to know it might help you too, Drew. If it wasn't for your spark and kick-start with this idea, I wouldn't have been inspired to run with this!
I'm thrilled to see it happening, after sadly looking through more than a decade of peoples intentions to start this project. I keep on wanting to make special items for this project with my 3D printer, and keep sadly looking on as I haven't quite gotten it tweaked in just yet.

#### shockie

##### High Plains Drifter
Alright, no glue here and somewhat the "exploded view" but I put together a first mockup with a clear BT50 section at the forward end to see how things should be placed internally for adequate spacing before I start cutting or permanently attaching. Then I decided if something was going to fail it would be in the forward section anyway, so my first version will actually look remarkably similar when assembled.

View attachment 439733

Two part nosecone may perhaps need some ballast when all done, perhaps not. 12" chute packaged with wadding. I used orange tape to make the two bearings more visible. These will nominally have significantly less tape at assembly and be rigidly mounted inside the red coupler seen just aft. A hollow aluminum rod runs through both creating an axel and also a blow through path. Then will have an appropriate length of BT50 to make up the scaled length. Also, I still need to figure out routing for a kevlar shock cord...maybe I'll anchor it to the axel loosely, notch the tape and route it through? Below you can see the aft section

View attachment 439734

BT50 tube, with the aluminum rod running axially. I have an 18mm motor mount with two centering rings, but I need to make sure the ejection charge vents where I want it to so I will use the punch out of the 18mm centering ring drilled for the rod to act as a cap and a centering ring itself.

Since this was the first look at how it would go together I haven't finalized lengths yet, but plan on cutting paper and aluminum tubing tomorrow. Then prepping, gluing, and final assembly. Fins will be cut from 1/8" balsa for this pass, but I need to work on shaping/canting for appropriate rotation rates. video of initial spin test below.

View attachment 439735

Not great spinning. Needs more mass further out (radially) to maintain the rotation better, however, I'll be able to check in front of a fan when I get some canards on. I think I'll start with a 10º cant and see how well it works in a flow field.
replace the moving parts with teflon .....super slick, no friction. material will allow for faster spin up and it will stay spinned due to its low friction coefficient. I would even use ptfe power to lube it before each flight

#### BrendanH69

##### Well-Known Member
TRF Supporter
Got some progress in on the Starstreak today after yesterday's diversion into making "Spoolin' Around" (see the WDYDRWT thread).

Drilled the transition through to the top of the AV Bay coupler (the Spider bay), and then I fitted 6 M4 threaded inserts to take the M4 attachment screws. Had to shim them about 3.5mm to keep all the useable threads and keep them just under the coupler surface. Just used some cutdown plastic Mac-shims and softened them with a heat gun to form them to shape.

Removed it after it's trial fit and then bolted the Dart (Hittile) carrier to the transition, and then fitted the two back to the AV Bay coupler.

Gonna have to start thinking more about the electronics, including where to place an arming switch. I'm toying with the idea of a rotary switch fitted to the transition, or a couple of internal switches with a single pull-pin & "Remove before Flight" flag.

Next jobs on the list:
• Tip to tip F/Glass on the canards (been putting it off!).
• Get my mate to 3D print some long launch rail guides and start the Dart stacking and alignment trials.
• Fit charge wells.
• Make a few vent holes and shear pin holes.
• Spray with filler primer and start sanding.
• Make up a long harness.
• Consider making and fitting a protective metal skin to the conical base of the dart carrier - a blast deflector of sorts.

#### BrendanH69

##### Well-Known Member
TRF Supporter
Got tired of looking at the part filled spirals on the main Bus body tube, so I started filling and sealing with spray putty primer/sealer and sanding, and sanding and.....

Also did a bit of filling on the transition and I've now given it a couple of light coats of base matt black. Going to try out this Chrome-like spray paint from a local auto shop and see how it goes.

Started the first tip to tip F/Glass on the Dart canards using some fine weave 98g/sq.m cloth, so time will tell on how this goes. Humidity is just over 90% and temp is down to 20 degrees C so I'm expecting long slow cures.

#### BrendanH69

##### Well-Known Member
TRF Supporter
Time to start thinking colour schemes as I start to seal and prime. A lot depends on how the chrome-like spray paint works out. Think I'll follow this photo as my guide:
• Dart carrier (upper core)- Aluminium/silver
• Darts - Chrome
• Dart carrier lower conical section - Chrome
• Transition - Chrome.
• BUS (sustainer) body, plus the fwd/aft outer rings - White
• Fins and fin can - Aluminium grey
• Booster - as per photo below.

#### DrewW

##### Well-Known Member
Time to start thinking colour schemes as I start to seal and prime. A lot depends on how the chrome-like spray paint works out. Think I'll follow this photo as my guide:
• Dart carrier (upper core)- Aluminium/silver
• Darts - Chrome
• Dart carrier lower conical section - Chrome
• Transition - Chrome.
• BUS (sustainer) body, plus the fwd/aft outer rings - White
• Fins and fin can - Aluminium grey
• Booster - as per photo below.

View attachment 462502
I was wondering what you were thinking since you are very obviously going to be at that stage before me.

#### BrendanH69

##### Well-Known Member
TRF Supporter
Used a bit of watered-down carpenter's filler to do a bit of "grain" filling on the F/Glass wrapped body and fins/canards of one of my Starstreak Darts. Hope to get one ready with a protective base coat of paint on it so I can give it a test flight at this Sunday's scheduled QRS launch day.

I've got a packet of curtain rail sliders from the local DIY store and will try to modify them to make mini rail guides for the Darts. Will then use this part of the dart carrier as the launch rail for the test flight.

Made up some decorative side panels to mimic the external shape of the Dart sabot locators and the side view of the separation system. Got one epoxied on so far. A base coat of high gloss black needs to go one before the attempt at the chrome paint.

#### BrendanH69

##### Well-Known Member
TRF Supporter
First go at applying the chrome paint to the dart carrier and transition. Wasn't expecting same result as the cap, but its not too bad for these parts, especially as it will get more fingerprints and dirt as I intend to use it for a test firing of the Dart with a C6-5 at tomorrow's QRS club launch day. OR indicates I need 10g more in the nose to get it to just about 1Cal stability, with 469ft predicted.

Got a packet of curtain rail guides from the DIY store for about A$2.50 and after a little bit of trimming with the Dremel and hobby knife, they have made suitable little rail guides. Expoxied them onto the first Dart (still in its gloss black undercoat). Spoolin' Around also gets its maiden flight tomorrow on a C6-3. OR predicts 110ft. #### DrewW ##### Well-Known Member First go at applying the chrome paint to the dart carrier and transition. Wasn't expecting same result as the cap, but its not too bad for these parts, especially as it will get more fingerprints and dirt as I intend to use it for a test firing of the Dart with a C6-5 at tomorrow's QRS club launch day. OR indicates I need 10g more in the nose to get it to just about 1Cal stability, with 469ft predicted. Got a packet of curtain rail guides from the DIY store for about A$2.50 and after a little bit of trimming with the Dremel and hobby knife, they have made suitable little rail guides. Expoxied them onto the first Dart (still in its gloss black undercoat).

Spoolin' Around also gets its maiden flight tomorrow on a C6-3. OR predicts 110ft.

View attachment 464284
View attachment 464285

#### BrendanH69

##### Well-Known Member
TRF Supporter
Interesting and reasonably successful launch day today at Cedar Grove, QLD.

Great interest in the Starstreak Dart, although RSO had concerns about it from it’s Dart Carrier mini rail (20cm long) and its probable low velocity off the rail. We discussed how to simulate a shorter rail in OR, so will look into that tonight.

As a result, I switched to a regular 1010 rail about 100cm long on a jawstand as my home made rail guides fitted it rail pretty well. So, it had it’s successful maiden flight off that with a C6-5 in it. The Micropeak altimeter reading were OK but a bit noisy on the way down. First flight reported as 315ft, quite a bit lower than the OR sim figure of 463ft.

#### Ez2cDave

##### Well-Known Member
TRF Supporter
Great interest in the Starstreak Dart, although RSO had concerns about it from it’s Dart Carrier mini rail (20cm long) and its probable low velocity off the rail. We discussed how to simulate a shorter rail in OR, so will look into that tonight.
Brendan,

When they are actually flown with the Booster, "speed off the rail" is immaterial, since they will already have velocity imparted by the Booster. At that point they are merely "upper stages" ( no "rail" required, at all, technically ).

Dave F.

#### DrewW

##### Well-Known Member
First flight reported as 315ft, quite a bit lower than the OR sim figure of 463ft.
Looks like you still had considerable upward velocity when your ejection charge popped. The timing of the delay is more than likely the culprit on the below projected altitude. Otherwise, looked like a very nice flight!

#### BrendanH69

##### Well-Known Member
TRF Supporter
When they are actually flown with the Booster, "speed off the rail" is immaterial, since they will already have velocity imparted by the Booster. At that point they are merely "upper stages" ( no "rail" required, at all, technically ).
Very true, Dave.
However for the first test flight yesterday, I was happy to keep the RSO happy and I was also lucky the home-made rail guides I made up the evening before were a suitable enough match for the 1010 rails available.
I did adjust the OR rail/rod length setting to 20cm in OR ( Edit>Preferences>Launch...) last night, and it appeared to have made no change at all to the velocity off the rod figure - still 12.6 m/sec.

The second flight yesterday was on one of the four longer HPR 1010 rails, which attracted a bit of fun as it was reckoned that this was the smallest rocket ever flown off that HPR rail/pad! Photo and video below, flight data to follow.

#### BrendanH69

##### Well-Known Member
TRF Supporter
Here's the graphs from the second test flight of the Starstreak Dart at the QRS launch day yesterday.

For the second test flight, I flew it with both of my Micropeak altimeters in it, plus I took the opportunity to drill two 2.9mm vent holes in the body prior to flying it. I'm convinced that one of the Micropeaks is a bit sensitive and giving more noisy readings.
Lower altitude achieved (286ft), but I'm going to partly put that down to a longer and somewhat dirtier rail than the first flight.