We launched this beast again last Saturday out at FAR and we had issues. It launched to 4K feet on a six grain 98mm sugar motor. It was a very windy day with 25mph surface winds. The winds did not impact the up or the down, but the surface drag on landing created a 15" airframe zipper and knocked loose all three fins.
The up part of this flight was perfect, as was the experimental spring-hinge nose and drogue release. This configuration is a two out the top HEDD configuration with a backup main chute in the aft compartment (under "FTS" radio pyro).
After the drogue released, the 5/8" kevlar line severed where it folds around the airframe. A padded protector had been sewn into the line, likely weakening the line. A few seconds later, the line failed again at the knot loop connecting the drogue to the nose, so the nose dropped without a chute. A good lesson that knots weaken any line by >50%. This drogue line had flown on the past flight successfully, so it is also possible that it was worn or weakened from that flight.
Without a drogue, the vehicle came in ballistic, reaching a speed of 282fps. The main chute latch released below 2k feet, but there was no drogue to pull it out and the vehicle was facing "nose down" so the air drag held the main in the upper airframe. We fired the FTS pyro backup, which separated the lower section and released the backup chute. The backup chute tangled (again!), but the pyro separation force was enough to push out the stuck main chute on top and it opened, while traveling 280 fps. The 14 foot main tore and lost a panel, but otherwise Ky's chute held up to the forces.
The rocket landed at a nice 24.5 fps, but ground winds thrashed it across the desert, creating a bad fin can zipper and tearing loose all three fins. The nose came down a few seconds later and surprisingly had only minor fiberglass damage.
We had four cameras on board (three survived) and three altimeter/telemetry systems, so we got a lot of good data. The two big lessons from this flight are... 1) we needed an even stronger kevlar drogue line (was a 5/8" 1500 lb test) configured without knots and 2) we should not have launched with high surface winds -- we had calculated and considered the up and down, but not the beating it would take on landing.
Here is the video... enjoy!
https://vimeo.com/manage/videos/685342633
Mike