Brief:
I chose t' model t' Explore 1 satellite as part o' EMRR Challenge 2008 – Simulation Challenge. Begad! Explorer 1 (officially titled at NASA as satellite 1958 Alpha) be t' first Earth satellite o' t' United States, matey, launched on February 1, ya bilge rat, 1958. Since this was me first real experience with RockSim, matey, 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. Arrr! 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, me hearties, 5.44" long
• 1 BT-55, arrr, 13.197" long
• 1 BT-20, me hearties, 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, matey, this be me first real experience with RockSim t' design a rocket from scratch. Arrr! I downloaded the demo version without issue. Ahoy! Havin' seen others use it I was pretty familiar t' functionality. Blimey! It didn't take long to get t' hang o' it and I be off and running. Begad! Begad! 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. Arrr! Avast! 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. Avast! Ahoy! 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! Aye aye! In this case t' software be a lot easier t' make these modifications than sandin' down t' BT-60 cone. Ahoy! OK, matey, ya bilge rat, shiver me timbers, enough whining-–I sanded t' balsa nose cone into t' diameter and shape I wanted. Aye aye! Next, 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. 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. Avast, me proud beauty!

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

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

I used t' EMRR shroud calculator t' help make t' two cones used t' form t' engine cone. Avast, me proud beauty! Blimey! 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. T' cone assembly was mounted t' t' BT-20 tube, ya bilge rat, shiver me timbers, arrr, then I epoxied the small cone t' t' BT-55 tube. Avast! Blimey! After this was dry, matey, I slid a centerin' rin' onto t' BT-20 and into t' large cone. This rin' will help support t' cone. Begad! Blimey!

T' original plan was t' attach t' Keelhaul®©™® shock cord t' t' engine motor mount, however, me bucko, me bucko, ya bilge rat, I forgot t' do this. Avast, me proud beauty! I will secure t' Keelhaul®©™® cord t' engine prior t' installin' t' engine. Well, blow me down! 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. Aye aye! This took a number of coats sandin' each smooth. Begad! Next, I added a couple o' coats o' white primer. Ahoy! Avast, me proud beauty! Next, ya bilge rat, 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! Begad! Next, arrr, I masked for the copper and painted these areas with Dark Copper (XF-28). Begad! After t' copper was dry I attached 3 clear Lexan fins. Finally, I clear coated t' entire model. Avast, me proud beauty!

Flight and Recovery:
It was basic flight prep with only one slight modification. Begad! T' Keelhaul®©™® shock cord was tied around t' motor prior t' installin' t' motor. Aye aye! I inserted t' motor (Estes C6-5) and taped it in place with Mylar type. Avast, me proud beauty! Next I added wadding, me hearties, arrr, rolled t' parachute, ya bilge rat, and stuffed t' lines. Avast! 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. 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, matey, me hearties, 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, by t' time I reached t' rocket the parachute be fully open after blowin' in t' wind for a few minutes. Aye aye! Ya scallywag! T' rocket came in fairly fast and broke a fin off on landing. Minor repairs are needed and t' rocket will be ready t' fly again.

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