Brief:

This is me second entry for t' EMRR “Spaceship Design Contest – 2009”. T' name I had previously used and planned t' submit be t' “T' Lifeboat” because o' t' intended use o' t' X-38, but durin' the launches today me cousin’s kids started callin' it “T' Love Boat”. Aye aye! So I decide t' change t' name to: THE LOVE BOAT. Begad! Aye aye!

Plans:

I based this design on last year’s design o' t' FWS rocket where t' engine tube sub-assembly ejects out t' aft o' t' rocket. Blimey! Begad! In this case used an 18mm engine rather than a cluster.

Construction:
Component Description:

• 030” Thick Polystyrene Sheet
• 1 - 1/4” Balsa Sheets
• 1 - 1/8” Balsa Sheets
• 1 – 3/16” Balsa Sheet
• 1 – BT20 - Main Engine Tube – 10.0” long
• 2 – BT20 – Main Support Tube – 6.0” long
• 2 - Yellow Tube – 1.0” long
• 1 - 1/8” Launch lugs
• 36” - 175 # Keelhaul®©™® String
• 24” - .375” elastic shock cord
• Nose weight
• 24” plastic parachute
• Fiberglass material & Epoxy
• Mylar Tape

Main Body Tube Assembly

I started by cuttin' t' BT20 tubes t' length (2 @ 6.0” and 1 @ 10.0”). I then cut out t' bulkhead from 1/8” balsa sheet (see template). Well, blow me down! Blimey! Blimey! I glued t' 3 tubes together side by side (see picture). Blimey! Blimey! I then slide the bulkhead in place and epoxied it t' t' tube sub-assembly. Avast, me proud beauty! Next, I glued a launch lug in t' center o' t' tube assembly. Ya scallywag! Arrr! Blimey! Finally, matey, I attached t' elastic shock cord t' t' main tube usin' 5 min epoxy t' secure it in place.

Vacuum Formed Shells

There are 3 separate vacuum formed pieces in this rocket. T' top half, bottom half, shiver me timbers, and cockpit. Well, blow me down! Ya scallywag! T' top and bottom halves were vacuum formed use t' shaped foam masters. Ya scallywag! Begad! T' cock pit is form over a balsa master (see pictures). Also see t' Tip on vacuum forming.

Body Assembly

I glued two .125” sheets o' balsa on edge t' form a 6” wide piece o' balsa. Begad! I glued t' top shell to t' 6” piece o' balsa. Ya scallywag! Next I trimmed t' balsa t' within 3/8” o' t' shell for t' front half and left the back half over hang. Avast! Well, blow me down! I then glued t' lower shell t' t' balsa sheet makin' sure t' 2 halves align as perfectly as possible.

Next, I cut out t' 2 side wings (see template A) from t' ¼” balsa. Ahoy! I rounded t' top and front edges o' each wing. Well, blow me down! Ya scallywag! Then I sand t' angle in each win' t' get t' appropriate look. Begad! Arrr! I epoxied wings in place and trimmed the excess o' t' .125” balsa up t' t' wings.

I used 5 minute epoxy around t' outside o' t' shell and balsa t' ensure a good strong joint.

I wasn’t happy with t' interface betwixt t' body and balsa wood wings so I decided t' apply fiberglass cloth t' this joint t' improve t' appearance as well as add strength.

Finally, ya bilge rat, me hearties, I trimmed t' cock pit section t' fit t' top o' t' shell and glued it in place. Well, blow me down!

Final Body & Tube Fittin'

T' launch lug hole needed t' be cut into t' shell – I slid t' main tube sub-assembly into t' shell assembly and usin' a lug rod t' mark t' location o' where t' hole needed t' be cut. Begad! I carefully used me Excato knife t' cut t' hole in t' shell. Begad!

I marked t' location o' t' tube subassembly so I could add bulkhead supports. I cut 4 - .125” x .25” pieces o' balsa and glued them in place t' resist t' engine thrust on t' bulkhead. Aye aye!

Nose Weight

I used 2 old engine tubes and filled each with 1 oz. Ya scallywag! o' weight each and secured it in place with Mylar tape at t' very end o' t' end o' t' 6” tube.

Finishin' Main Body Assembly

I sprayed 2 or 3 coats on t' entire shell assembly with Rust-oleum White Plastic Primer #209460. Ya scallywag! After lightly sandin' t' primer, arrr, shiver me timbers, me bucko, I sprayed white gloss (Testors Gloss White #4696 ). Avast, me proud beauty! Next, matey, I masked t' bottom area for t' black and sprayed gloss black (Testors Acryl #4695). Ahoy! After t' black, I added NASA decals. Finally, I added 2-3 coats of Krylon Crystal Clear Gloss.

Decals

I printed t' decals on Experts-Choice clear water slide decal material. Avast, me proud beauty! Begad! I cut them out and applied them as the pictures shows.

Flight:
Flight Prep & Flight Results

I made t' first o' t' 3 flights in March – this rocket was nay painted. Today, I planned t' do at least 2 more flights today after paint. I did a spin test and found that after paint I needed t' add a little more nose weight.

I added dog barf, matey, folded t' parachute, ya bilge rat, and loaded t' engine sub-assembly. Avast! Once in place I added a C6-3 engine. I slid t' “Love Boat” on t' launch rod. 5-4-3-2-1----- blast off. Well, blow me down! T' boost was good, but nay as high as I thought it would have been. T' parachute ejected and opened with a good recovery. Arrr! T' second flight (C6-3) was a little better with more altitude. Begad! By t' time, I recovered t' rocket it be just about dark so I decided t' nay t' 3 flight today, shiver me timbers, ya bilge rat, but did get 3 good flights with this rocket.

Summary:
Pro’s – NASA needs a better paint scheme.

Con’s – None

Other:
Thanks EMRR - this was a great project. Arrr! Ahoy! I enjoyed t' design and construction challenges. I am lookin' forward to 2010’s spaceship challenge.