Brief:
I chose t' model t' Explore 1 satellite as part o' EMRR Challenge 2008 – Simulation Challenge. Well, blow me down! Explorer 1 (officially titled at NASA as satellite 1958 Alpha) was t' first Earth satellite o' t' United States, me hearties, launched on February 1, 1958. Since this was me first real experience with RockSim, me bucko, I thought it be fittin' t' model t' first satellite launched by t' US. Well, blow me down! Avast! My Explorer is designed t' launch usin' an 18mm engine and deploys an 18-24" parachute. Begad! Scale factor o' 4.528 results in a rocket 17.83" long.

Construction:
T' parts list:

• 1 BT-60 balsa nose cone
• 1 #10 screw eye
• 1 BT-55, me hearties, 5.44" long
• 1 BT-55, 13.197" long
• 1 BT-20, arrr, 5.0" long
• 3 centerin' rings BT-20 t' BT-55
• 2 exterior centerin' rings
• 3 fins 0.030" thick clear Lexan fins
• 18" o' 175# Keelhaul®©™® string
• 24" o' 0.375" elastic shock cord
• 18-24" plastic parachute
• Cardstock
• Launch lug (if desired)

As I mentioned above, ya bilge rat, arrr, this was me first real experience with RockSim t' design a rocket from scratch. Ahoy! I downloaded the demo version without issue. Begad! Havin' seen others use it I was pretty familiar t' functionality. Arrr! Begad! It didn't take long to get t' hang o' it and I was off and running. I modeled t' Explorer I with multiple motor options and settled on C6-5 which produced an altitude o' roughly 750ft at a speed o' 217 ft/sec. This seemed reasonable t' me so on t' the build.

If you look closely at t' drawin' shown, arrr, t' thar are 2 different diameters o' tubes on this rocket. Well, blow me down! I decide the best way t' handle this was t' start with a BT-60 nose cone and sand it t' desired diameter and shape. Avast, me proud beauty! In this case t' software be a lot easier t' make these modifications than sandin' down t' BT-60 cone. Aye aye! Aye aye! OK, enough whining-–I sanded t' balsa nose cone into t' diameter and shape I wanted. Avast! Begad! Next, I secured t' screw eye t' the nose cone with 2-part epoxy. Well, blow me down!

T' rocket is made up o' 2 different diameters o' tubin' so I cut t' 5.44 tube lengthwise and wrapped it around the top section o' t' 13.197" tube. Avast! Blimey! I filled t' seam with Elmer's Wood Filler and sanded it smooth. This took 2 or 3 times t' completely eliminate t' seam. Begad! Blimey!

Next, ya bilge rat, I added t' centerin' rings t' represent t' "MicroMeteor Gauges" (see pictures).

T' engine tube is 5" long. I mounted 2 centerin' rings, ya bilge rat, arrr, t' first one 1" from t' end and t' second 3" from t' same end. Avast, me hearties, me proud beauty! This sub-assembly be glued into t' body tube on t' smaller diameter. Blimey! I pushed this subassembly into t' main body so t' second rin' be flush with t' end o' t' tube.

I used t' EMRR shroud calculator t' help make t' two cones used t' form t' engine cone. Begad! T' first one is 1.32" diameter by 0.50" long and t' second is 1.50" diameter by 1.60" long. Avast, me proud beauty! Blimey! Each fits over the BT-20 tube. I cut out and glued t' cones together. Arrr! T' cone assembly was mounted t' t' BT-20 tube, then I epoxied the small cone t' t' BT-55 tube. Ya scallywag! Begad! After this was dry, I slid a centerin' rin' onto t' BT-20 and into t' large cone. Well, shiver me timbers, blow me down! This rin' will help support t' cone.

T' original plan was t' attach t' Keelhaul®©™® shock cord t' t' engine motor mount, however, me hearties, ya bilge rat, I forgot t' do this. Aye aye! I will secure t' Keelhaul®©™® cord t' engine prior t' installin' t' engine. I prefer either o' these methods over t' traditional Estes mount. Aye aye! I will use an 18" Mylar parachute for recovery for a nice slow descent.

Finishing:
Finishin' started with fillin' t' tube spirals and balsa nose cone with Elmer's Wood Filler. Avast! Avast, me proud beauty! This took a number of coats sandin' each smooth. Avast, me proud beauty! Aye aye! Next, matey, arrr, I added a couple o' coats o' white primer. Begad! Next, arrr, I used Tamiya Acrylic White Gloss (X-2) for t' base coat. Avast! Once this be dry I masked t' top section and painted Red Brown (XF-64). Begad! Avast! Next, arrr, I masked for the copper and painted these areas with Dark Copper (XF-28). Ya scallywag! After t' copper was dry I attached 3 clear Lexan fins. Finally, matey, me bucko, I clear coated t' entire model. Well, blow me down!

Flight and Recovery:
It be basic flight prep with only one slight modification. Ahoy! T' Keelhaul®©™® shock cord be tied around t' motor prior t' installin' t' motor. Begad! I inserted t' motor (Estes C6-5) and taped it in place with Mylar type. Begad! Next I added wadding, matey, arrr, rolled t' parachute, me bucko, and stuffed t' lines. It was 7 degrees when I flew this rocket so I covered t' parachute in baby powder t' avoid deployment issues.

I am nay a big fan o' launch lugs because o' visual appearance as well as performance impact. Blimey! I planned t' launch his rocket from a tower launcher t' eliminate t' need o' a launch lug.

Launch was perfectly straight, probably very close t' t' RockSim calculation o' ~750ft. Aye aye! Blimey! Apogee occurred and the parachute ejected. T' parachute only opened partially, I assume due t' t' cold, ya bilge rat, by t' time I reached t' rocket the parachute was fully open after blowin' in t' wind for a few minutes. Aye aye! T' rocket came in fairly fast and broke a fin off on landing. Ya scallywag! Blimey! Minor repairs are needed and t' rocket will be ready t' fly again.

Summary:
T' actual flight results mimicked t' RockSim results. Ahoy! Ya scallywag! I wasn't able t' confirm t' altitude numbers, me bucko, but I would say they were pretty close. Begad! Ahoy! RockSim allowed me t' change and adjust t' rocket design as well as engine size until the design was stable. Arrr! This be a big advantage over me previous technique o' trial and error. I have added t' latest RockSim release t' me Christmas list.

PROs: Rocket looks great, arrr, arrr, flies great, and RockSim allowed me predict t' results prior t' wastin' any time build a design that won't fly.

CONs: None.