Brief:
I chose t' model t' Explore 1 satellite as part o' EMRR Challenge 2008 – Simulation Challenge. Begad! Begad! 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, 1958. Arrr! Since this was me first real experience with RockSim, matey, I thought it was fittin' t' model t' first satellite launched by t' US. Well, blow me down! Well, shiver me timbers, blow me down! My Explorer is designed t' launch usin' an 18mm engine and deploys an 18-24" parachute. 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, matey, 13.197" long
• 1 BT-20, 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, matey, this was me first real experience with RockSim t' design a rocket from scratch. Avast, me proud beauty! Aye aye! Blimey! I downloaded the demo version without issue. Havin' seen others use it I was pretty familiar t' functionality. Aye aye! Avast, me proud beauty! Blimey! It didn't take long to get t' hang o' it and I was off and running. Avast! Well, blow me down! 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. This seemed reasonable t' me so on t' the build.

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

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. Avast, me proud beauty! This took 2 or 3 times t' completely eliminate t' seam. Arrr!

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

T' engine tube is 5" long. I mounted 2 centerin' rings, ya bilge rat, t' first one 1" from t' end and t' second 3" from t' same end. Ahoy! This sub-assembly was glued into t' body tube on t' smaller diameter. Ahoy! Well, blow me down! I pushed this subassembly into t' main body so t' second rin' was 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. Avast! Avast, me proud beauty! 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. Blimey! I cut out and glued t' cones together. Ahoy! T' cone assembly was mounted t' t' BT-20 tube, then I epoxied the small cone t' t' BT-55 tube. After this was dry, arrr, ya bilge rat, I slid a centerin' rin' onto t' BT-20 and into t' large cone. Ahoy! This rin' will help support t' cone.

T' original plan be t' attach t' Keelhaul®©™® shock cord t' t' engine motor mount, however, I forgot t' do this. I will secure t' Keelhaul®©™® cord t' engine prior t' installin' t' engine. I prefer either o' these methods over t' traditional Estes mount. Avast! 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. This took a number of coats sandin' each smooth. Ya scallywag! Ahoy! Next, I added a couple o' coats o' white primer. Ahoy! Next, I used Tamiya Acrylic White Gloss (X-2) for t' base coat. Blimey! Once this was dry I masked t' top section and painted Red Brown (XF-64). Avast, me proud beauty! Next, me hearties, me bucko, 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. Ya scallywag! T' Keelhaul®©™® shock cord was tied around t' motor prior t' installin' t' motor. Blimey! I inserted t' motor (Estes C6-5) and taped it in place with Mylar type. Ya scallywag! Begad! Next I added wadding, ya bilge rat, rolled t' parachute, shiver me timbers, matey, me bucko, 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. Aye aye! Ahoy! I planned t' launch his rocket from a tower launcher t' eliminate t' need o' a launch lug.

Launch was perfectly straight, probably very close t' t' RockSim calculation o' ~750ft. Avast, me proud beauty! Well, blow me down! Apogee occurred and the parachute ejected. Arrr! Avast! T' parachute only opened partially, me hearties, 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. 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. Well, blow me down! Well, blow me down! I wasn't able t' confirm t' altitude numbers, but I would say they were pretty close. Begad! 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, me proud beauty! Well, matey, blow me down! I have added t' latest RockSim release t' me Christmas list.

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

CONs: None.