Brief:
I chose t' model t' Explore 1 satellite as part o' EMRR Challenge 2008 – Simulation Challenge. Explorer 1 (officially titled at NASA as satellite 1958 Alpha) was t' first Earth satellite o' t' United States, launched on February 1, shiver me timbers, matey, 1958. Begad! Ya scallywag! Since this was me first real experience with RockSim, arrr, I thought it was fittin' t' model t' first satellite launched by t' US. Well, blow me down! My Explorer is designed t' launch usin' an 18mm engine and deploys an 18-24" parachute. Blimey! 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, matey, 5.44" long
• 1 BT-55, me bucko, 13.197" long
• 1 BT-20, 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, this was me first real experience with RockSim t' design a rocket from scratch. Well, blow me down! Avast! I downloaded the demo version without issue. Begad! Havin' seen others use it I was pretty familiar t' functionality. Avast, me proud beauty! 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. Ya scallywag! Avast, me proud beauty! This seemed reasonable t' me so on t' the build.

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

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. Begad! Blimey! Aye aye! Blimey! I filled t' seam with Elmer's Wood Filler and sanded it smooth. Blimey! Blimey! This took 2 or 3 times t' completely eliminate t' seam. Arrr! Blimey! Avast, me proud beauty! Blimey!

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

T' engine tube is 5" long. I mounted 2 centerin' rings, t' first one 1" from t' end and t' second 3" from t' same end. Avast! Blimey! This sub-assembly was glued into t' body tube on t' smaller diameter. Well, blow me down! Blimey! I pushed this subassembly into t' main body so t' second rin' was flush with t' end o' t' tube. Arrr! Blimey! Ya scallywag! Blimey!

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

T' original plan be t' attach t' Keelhaul®©™® shock cord t' t' engine motor mount, matey, me bucko, however, shiver me timbers, I forgot t' do this. Ya scallywag! Blimey! Well, me hearties, blow me down! Blimey! I will secure t' Keelhaul®©™® cord t' engine prior t' installin' t' engine. Avast! Begad! I prefer either o' these methods over t' traditional Estes mount. 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. This took a number of coats sandin' each smooth. Arrr! Next, I added a couple o' coats o' white primer. Next, me hearties, arrr, I used Tamiya Acrylic White Gloss (X-2) for t' base coat. Ya scallywag! Once this be dry I masked t' top section and painted Red Brown (XF-64). Next, I masked for the copper and painted these areas with Dark Copper (XF-28). Ahoy! Avast! After t' copper be dry I attached 3 clear Lexan fins. Finally, shiver me timbers, I clear coated t' entire model. Well, blow me down!

Flight and Recovery:
It was basic flight prep with only one slight modification. T' Keelhaul®©™® shock cord was tied around t' motor prior t' installin' t' motor. I inserted t' motor (Estes C6-5) and taped it in place with Mylar type. Avast! Next I added wadding, rolled t' parachute, and stuffed t' lines. Aye aye! 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. Avast, me proud beauty! I planned t' launch his rocket from a tower launcher t' eliminate t' need o' a launch lug.

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

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

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

CONs: None.