Highpower Rocket Build

[TZ250]

**Mods** : If this is the wrong area, please move it to the correct area.

This is highpower rocket. Highpower rockets require certification to buy motor, a licensing procedure to fly them, insurance for the rocket and any damage it may cause, and must comply with NFPA, FAA and FCC regulations.

This rocket will be almost 8 ft. tall. This is a Level 2 rocket. I've built a Level 1 rocket, but I'm waiting for the cert. flight date. Level 2 licenses require a written test in addition to a certification flight.

The Giant Leap Rocketry 4” Talon is a cool kit. I bought the fiberglass version and I’m glad that I did. I made one significant change; I opted to use a 54mm Aeropack motor retainer instead of the Slimline that the Talon was designed for.

I must give credit where credit is due: Bob Mosley at Aeropack and Kent Burnett at Giant Leap Rocketry have been fantastic to deal with. Both have politely (and patiently!) answered my phone calls and emails. They both possess a great deal of knowledge and they’re glad to help. I spent a lot of time with Mr. Mosley on the phone as he explained the details of the conversion. FYI, the conversion was my idea. I liked the Aeropack retainer on my Wildman Dark Star Lite, so I wanted to have the same style on my Talon.

Mr. Mosley explained what had to happen to make the Aeropack RA54P retainer fit. He was well ahead of me at that time. Although it seems simple now, I didn’t immediately understand the process. The 4” Talon orignally used two centering rings in the airframe, and the tailcone is epoxied to the Slimline retainer. It is designed for the Slimline to be a centering ring. I had to make a third centering ring that would fit just above the RA54P. I approximated the angle of the tailcone to be 5.5°.

A good (great!) friend owns a machine shop. I stopped by on Monday of this week to show him the Talon kit. He said that Tuesday would be a good day for me to machine my parts because he was planning to spend the day taking care of paperwork. We cut the tailcone shorter so that it would clear the Aeropack RA54P. We then measured to the top of where the new centering ring was going to fit. I had some leftover ¾” oak and thought that it would make a good centering ring. Tom cut the oak on his 3 axis CNC mill.

The Beginning
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4201_1000_A.jpg

U-Bolts are stronger than rolled eye bolts
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4212_1000_A.jpg

Custom Made Centering Ring on a CNC Mill
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4206_1000_A.jpg

I then cut the 5.5° taper on a lathe. I left the centering slightly over sized so that I could sand it to fit the tailcone. While I was there I also used the drillpress to bolt the stainless steel U-Bolt to the top centering ring. I used Loc-Tite on the nuts, then later epoxied them into place. I had to sand the edges of the washers to make them fit inside the airframe.

Lathe Work
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4217_1000_A.jpg

Front View
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4219_1000_A.jpg

Preliminary Measurements
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4221_1000_A.jpg

The next day I sanded the I.D. of the new centering ring for a better fit. The tapered centering ring was sanded on the outside edge until it fit inside the tailcone at the correct depth. That way, the RA54P and tapered centering ring will be (are now) epoxied with JB Weld to the motor tube. The outer edge of the top surface of the tapered centering ring is epoxied to tailcone. Everything is concentric and strong.

When I fit the motor tube/airframe/tailcone assembly together I had a 54mm-38mm adapter in the motor mount and also a Aerotech 38-720 in place. That way I wouldn’t be surprised with fit issues later on. I had to widen the slots about .010”. The fins fit perfectly now. The airframe was cleaned inside and outside with alcohol to remove oil and sanding debris.

Test Fit
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4236_1000_A.jpg

Thousandths Matter
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4241_1000_A.jpg

.010" Bigger
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4244_1000_A.jpg

[TZ250]

Naturally, I sanded around the fin slots so that the epoxy would have more surface area to adhere to. I also sanded inside the airframe around the slots and where the centering rings would go. It was great to reach inside the airframe! I also drilled holes so that I could inject epoxy onto the centering rings. I don’t know if it needed it, but the CR’s have epoxy fillets top and bottom. I did not use the stick method that GLR mentions. I poured epoxy on a 3/16” dowel and let it run down to the top surface of the top motor mount. The centering rings were slightly loose when the motor tube was in the correct position. I used a wood clamp to hold the bottom centering ring and airframe together until the epoxy cured.

Third Hand
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4252_1000_A.jpg

After that, I removed the tailcone and inverted the booster. I poured epoxy onto the bottom surface of the middle CR and injected epoxy onto the bottom surface of the top CR. Speaking of epoxy I used Pro Line epoxy from Wildman. It is very thin and runny so it required more colloidal silica than the System Three epoxy that I used last time. This time I bought the West System mini-pump set. It was so easy to mix that I kept checking everything to make sure that I had the correct ratios. It will be a long time before I weigh epoxy!

I Made A Mess!
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4267_750_A.jpg

I'll Never See The Motor Tube Again
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4261_1000_A.jpg

I also drilled a hole for epoxy through the tailcone. This epoxy joined the outside of the tapered centering ring to the tailcone. Next week I’ll fill this area with Mega-Foam. I would feel better with fiberglass tailcone and nosecone, but this will do.

The booster is now finished. That was the most difficult part of the build because I couldn’t use GLR numbers once I cut the tailcone. I was on my own to establish reference points. It wasn’t hard, but it added to the build time.

I'll post more pictures of the build soon. For now, I need to get back to normal life! I've been staying up late working on numbers, then checking the dry assembly, then epoxying everything together. (Is epoxying a verb?)

I still need to buy some supplies, but they will have to wait. I need parachutes, altimeters and a CTI 6XL case and motor. It will certify on a Aerotech J350.

I used a Dremel to widen the slots .005" per side. I like fiberglass rockets!
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4250_1000_A.jpg

[cstreu1026]

Very cool!

[TZ250]

For comparison’s sake, this is my first highpower rocket next to my second.
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4275_300_A.jpg

I epoxied the airframe coupler, av bay, into the upper airframe. This area has to be clean because the bulkheads seal against this surface and because it slips into the upper part of the lower airframe. I carefully applied epoxy into the airframe, trying to make sure that I didn’t have too much. I did. That wasn’t a problem because I wiped the excess off with alcohol. The outside stayed clean.

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4301_375_A.jpg

The Proline epoxy gets hot! Small batches haven’t melted my cheap plastic cups, but a large batch created significantly more heat.

Hot Stuff!
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4294_942_A.jpg

I tried to keep some forward momentum, so I built the electronics sled. The width of the G10 is slightly tapered, but that won’t affect it’s function. It has about ¼” clearance per side. I measured the bolt hole spacing in the bulkheads, which is 1.620”. To keep everything perfectly centered I needed 0.611” under the outside of the brass tube. One of my sets of setup blocks is 0.620”, so I used it. What’s .009” between friends? I realize that the sled doesn’t require this amount of precision, but the blocks are a convenient way to hold everything together. I was working by myself. I tacked the brass tube in place with Super Glue and carried it outside for a picture. After this was taken I mixed some epoxy and added a 0.175” fillet the length of the tube, on the top surface. If I had thought more, I would have flipped the sled and installed the fillet on the bottom. That way I would have been able to stack blocks on top of the brass tube. The way I did it required extra thought and time. I couldn’t stack blocks on top of the tube because the fillet was now there.

Third and Fourth Hands
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4284_1000_A.jpg

I then got an angle plate and placed it on my surface plate. I used the same surface for all measurements to make sure that the brass tubes remained parallel. Since I needed a spacing of 1.620”, I used another setup block and placed a 1.000” parallel on top of that. The spacing is perfect and the brass tubes are parallel. I then tacked the top of the brass tube with Super Glue and added a 0.175” fillet to the top surface. After that had cured, I flipped the sled and placed two fillets on the bottom side of the brass tubes. I let them cure at an angle to help the epoxy flow better.

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4307_1000_A.jpg

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4304_1000_A.jpg

Curing Phase
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4311_1000_A.jpg

Even though it's going to certify with single deployment, I started working on the AV bay. I used a fancy extension for my shop vac to help hold things together. Neither would fit. I noticed that they both rocked in one area. I measured the diameter and discovered that both were 0.025" out of round. My Dremel is the go-to tool for this type of work. Once that was solved, everything came together quickly. With the AV bay at the top, I placed a wood disc inside the airframe, resting on the shop vac extension. I then placed some Titebond wood glue on the inner disc and dropped in from the top. I used the all-thread to align the holes for the all-thread. I placed a weight, really just a tube of Liquid Nail, on top to slightly compress them. This method kept the two discs concentric. The next day I installed U-bolts instead of the rolled eye bolt that came with it. The discs are starting to get cramped for space now, but I still have enough room for the charge canisters.

Soon, I'll sand the airframe because it's convenient to do without fins. The fins should be installed later this week. After that, it will be ready for the L2 cert. flight.

Note Fancy Tools Used
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4495_229_A.jpg

Parachute Attachment Point
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4501_A.jpg

The lower fins and one upper fin are tacked into place. I 'buttered' the root edge where the fin contacts the motor tube, per Giant Leap instructions. I did that several times, per Giant Leap instructions, to make sure that there was plenty of epoxy on the root edge. I also left a few small dabs of epoxy between the fin and airframe.

I made one mistake during the fin installation. I forgot to bevel the edges of the first fin before installing it. I beveled the remaining fins before they were installed. I'll sand the bevel on the first fin by hand once all of the epoxy has cured.

I used right-angle aluminum channel as a guide. The channel has a slot cut in it that is .096" wide. I used bungee cords to keep the right-angle channel centered and tight while the epoxy was curing.

I'm going to epoxy one more large fin tonight. I'll tack the other one in the morning. After that, I'll start injecting epoxy. After that, I'll finish with the exterior fillets.

The hard part of the build is finished. All that's left is recovery gear and paint.

[TZ250]

First Fin Tacked Into Position
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4515_1000_A.jpg

Getting Closer
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4524_1000_A.jpg

The fins are now in the correct location. I still need to add the external fillets, but that is the easy part.

I drilled holes into the airframe next to the fin slots so that I could inject epoxy. I wanted a small amount of epoxy on the motor tube/fin joint. That is now complete. I'm still debating on whether or not I'll add epoxy to the inside of the airframe where it meets the fin. A small amount would be okay. Weight gain is minimal; we're talking about grams.

A couple of the holes are farther from the slot than I intended. The .375" (3/8") radius of the spoon will barely cover a couple of the holes. I'll probably use a .5" radius for the fillet. That is the radius of the handle of the plunger of the syringe. That's why it's included in the picture.

It's been a fun rocket to build. I enjoy building rockets as much as I enjoy flying them!

Fancy Radius Tool! (not used)
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4531_1000_A.jpg

Ready for Structural Fillets
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4538_1000_A.jpg

2/3 of the fillets have been applied. I would say 'finished' but they need a little sanding. I used colloidal silica to thicken the epoxy. Proline epoxy is very thin compared to the System Three that I used for my Dark Star Lite. I had some clumps that can be seen in the final fillet. This is a snapshot of the first set of fillets. I made sure to thoroughly mix the silica for the second set. The second set is smoother. My System Three fillets were immediately as smooth as glass. These will need to be sanded. I'll use a 1" dowel to keep the same radius.

The bumps are only a few thousandths above the surface. It will take very little sanding to make them perfect. One more set to go! I'll take care of those tomorrow morning. I hope to have them sanded by the end of the weekend. I now need parachutes, then I can try to certify for L1 and L2. It will probably certify without paint. Later, I'll buy altimeters and set it up for dual deploy.

The parallel lines are a result of sunlight coming through the windows of the garage door. The lines are the areas between the windows.

Soon to be as smooth as glass
http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4558_1000_A.jpg

[ibstrokin]

Now that's a build thread!!!! It's nice to know there is a Rocket Scientist in the family.

[Metcalf Racing]

I just read this and WTF...... I just... I don't even know what to say. Its definitely cool but dude you've got way to much time on your hands. I read 80% of this thinking you thought you were going to be inside of it

[Mustard]

Thats some cool shit right there!

[draggin50]

Whats the flight distance of something like that? Any warheads gonna be mounted on it? That would be cool as hell!

[TZ250]

Whats the flight distance of something like that? Any warheads gonna be mounted on it? That would be cool as hell!

It will go about 10,000 ft. high. No warheads. That would be a felony! :lol:

I'm going to try to mount a video camera to the rocket. For the J350, the camera should stay on. With the L935 motor, the camera may come off because of the speed of the rocket. I have an idea that may keep it attached.

Once I record the video's, you'll see them here.

[87stangbbb]

I just read this and WTF...... I just... I don't even know what to say. Its definitely cool but dude you've got way to much time on your hands. I read 80% of this thinking you thought you were going to be inside of it
lmao i about fell asleep going thru it.

[TZ250]

Here it is, almost ready to fly. Max. speed will be 760 MPH. (Mach 1.00)

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/Rockets/DSC_4577_500_A.jpg

[ibstrokin]

So if it goes mach 1, will it break the sound barrier, and make a sonic boom? Or will you just have to wait and see?

[TZ250]

So if it goes mach 1, will it break the sound barrier, and make a sonic boom? Or will you just have to wait and see?

It will make a sonic boom. It may be difficult to hear because the sound of the exhaust will be loud.

[bbfstanger]

set that sucker in the frt yard and mess with the neighbors lol!

[sean]

when are you launching it and where. If your close i may come out if you dont mind. That looks cool.

[TZ250]

when are you launching it and where. If your close i may come out if you dont mind. That looks cool.

I plan to launch it Oct. 18. The launch will be near the Bob Evan's farm. Or, if I have to wait, there will be a launch northeast of Springfield. The initial launch will be on the minimum motor required for L2 certification. After that, I'll save my pennies and buy a big motor.

Sean, your welcome to come out. Rocket launches are open to the public.

[Maximus]

Very cool!! :bigthumb

[BlazinEagle]

That is cool as hell! I loved shooting off rockets as a kid. October sky!

[bbfstanger]

if you go up here by spfld let me know i might come out and watch it.
i used to build them old tester rockets when i was a kid

[cstreu1026]

if you go up here by spfld let me know i might come out and watch it.
i used to build them old tester rockets when i was a kid

^^^^What he said^^^^
If its close by I wouldn't mind coming out to watch it fly.

[TZ250]

This is the rockets first flight and it's the certification flight for Level 2. This motor is considered minimum for this rocket. The next several flights will be have motors that are considerably more powerful. With the big one it will see just over Mach 1 as a top speed.

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/DSC_5246_1000_A.jpg

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/DSC_5247_1000_A.jpg

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/DSC_5248_1000_A.jpg

http://i561.photobucket.com/albums/ss58/TZ250Fanatic/DSC_5249_1000_A.jpg

[ibstrokin]

This is Ground Control to Major Tom!!!!!!!! Cool pics

[draggin50]

Man thats bad ass!!! Cool pictures!

[Katmandu]

Didn't you used to work for Saddam Hussein ? J/K!!

Man! You gotta let us know when/where you going to shoot these things! I would LOVE (and bunch other folks) to see these things fly!

When is your next launch ?

What's something like this cost ?

I too used to build model rockets when I was a kid. Fun as hell! :bigthumb

[INSANEBA]

Thats nuts! I say we get a jat motor and strap it in the back of a hatchback and go play!!! lol

[pegasus]

man thats cool I was big into bulding "small model rocks" when I was a kid the last one i was working on was a 2 stage using 4 D size engines i wooped ass in 4h with them even made it to the state fair a few times