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

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. Arrr! 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!

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

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

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

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

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

Summary:
T' actual flight results mimicked t' RockSim results. Aye aye! I wasn't able t' confirm t' altitude numbers, me hearties, 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 be stable. Well, blow me down! This was a big advantage over me previous technique o' trial and error. Well, shiver me timbers, blow me down! I have added t' latest RockSim release t' me Christmas list.

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

CONs: None.