Brief:
I chose t' model t' Explore 1 satellite as part o' EMRR Challenge 2008 – Simulation Challenge. Avast! Explorer 1 (officially titled at NASA as satellite 1958 Alpha) was t' first Earth satellite o' t' United States, arrr, launched on February 1, matey, matey, 1958. Begad! Since this was me first real experience with RockSim, me hearties, I thought it be fittin' t' model t' first satellite launched by t' US. Avast! My Explorer is designed t' launch usin' an 18mm engine and deploys an 18-24" parachute. Arrr! 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, arrr, 5.44" long
• 1 BT-55, me bucko, 13.197" long
• 1 BT-20, matey, shiver me timbers, 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, me bucko, this be me first real experience with RockSim t' design a rocket from scratch. I downloaded the demo version without issue. Avast! Havin' seen others use it I was pretty familiar t' functionality. It didn't take long to get t' hang o' it and I be off and running. Arrr! 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. Blimey! Begad! 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. Aye aye! Blimey! I decide the best way t' handle this be t' start with a BT-60 nose cone and sand it t' desired diameter and shape. Ya scallywag! In this case t' software be a lot easier t' make these modifications than sandin' down t' BT-60 cone. Arrr! OK, matey, arrr, enough whining-–I sanded t' balsa nose cone into t' diameter and shape I wanted. Ya scallywag! Avast, me proud beauty! Next, matey, I secured t' screw eye t' the nose cone with 2-part epoxy. Well, blow me down! Arrr!

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. I filled t' seam with Elmer's Wood Filler and sanded it smooth. Begad! This took 2 or 3 times t' completely eliminate t' seam.

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

T' engine tube is 5" long. Ya scallywag! I mounted 2 centerin' rings, t' first one 1" from t' end and t' second 3" from t' same end. Ya scallywag! This sub-assembly was glued into t' body tube on t' smaller diameter. Avast, me proud beauty! 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. Blimey! Aye aye! T' first one is 1.32" diameter by 0.50" long and t' second is 1.50" diameter by 1.60" long. Blimey! Each fits over the BT-20 tube. Aye aye! Aye aye! I cut out and glued t' cones together. Well, blow me down! Arrr! T' cone assembly was mounted t' t' BT-20 tube, matey, then I epoxied the small cone t' t' BT-55 tube. After this be dry, I slid a centerin' rin' onto t' BT-20 and into t' large cone. Well, blow me down! This rin' will help support t' cone. Blimey!

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

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

Launch was perfectly straight, arrr, ya bilge rat, probably very close t' t' RockSim calculation o' ~750ft. Aye aye! Apogee occurred and the parachute ejected. Ya scallywag! 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. Avast, me proud beauty! T' rocket came in fairly fast and broke a fin off on landing. Begad! Minor repairs are needed and t' rocket will be ready t' fly again.

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

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

CONs: None.