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, matey, launched on February 1, me hearties, 1958. Ya scallywag! Blimey! Since this be me first real experience with RockSim, ya bilge rat, I thought it was fittin' t' model t' first satellite launched by t' US. Begad! Blimey! My Explorer is designed t' launch usin' an 18mm engine and deploys an 18-24" parachute. Avast! Blimey! Avast! 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, ya bilge rat, 5.44" long
• 1 BT-55, matey, 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, me hearties, this was me first real experience with RockSim t' design a rocket from scratch. Avast, me proud beauty! I downloaded the demo version without issue. Begad! Blimey! Havin' seen others use it I be pretty familiar t' functionality. It didn't take long to get t' hang o' it and I be off and running. Blimey! Ya scallywag! Blimey! 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. Aye aye! 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. Avast, me proud beauty! Begad! 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. In this case t' software be a lot easier t' make these modifications than sandin' down t' BT-60 cone. Arrr! OK, me bucko, enough whining-–I sanded t' balsa nose cone into t' diameter and shape I wanted. Ya scallywag! Ahoy! Next, arrr, I secured t' screw eye t' the nose cone with 2-part epoxy. 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. Ya scallywag! Avast, me proud beauty! Blimey! I filled t' seam with Elmer's Wood Filler and sanded it smooth. Begad! Blimey! Blimey! This took 2 or 3 times t' completely eliminate t' seam. Aye aye! Blimey!

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

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

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

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

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

Launch was perfectly straight, me bucko, probably very close t' t' RockSim calculation o' ~750ft. Apogee occurred and the parachute ejected. Ahoy! Avast! Blimey! T' parachute only opened partially, I assume due t' t' cold, matey, me bucko, me hearties, by t' time I reached t' rocket the parachute was fully open after blowin' in t' wind for a few minutes. Blimey! T' rocket came in fairly fast and broke a fin off on landing. Aye aye! 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. RockSim allowed me t' change and adjust t' rocket design as well as engine size until the design was stable. Avast! This was a big advantage over me previous technique o' trial and error. Avast! I have added t' latest RockSim release t' me Christmas list.

PROs: Rocket looks great, matey, shiver me timbers, 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.