TERMINATOR 5

BILL RILEY
TRIPOLI LEVEL 3
CERTIFICATION PROJECT

Bill Riley
Tripoli #12294 RocketRiley@ip-mail.net
Bill Riley
Terminator 5
Tripoli Level 3 Certification Project

Table of Contents
Rocketry Warehouse Terminator 5............................................................................................................... 3
Project Description and Objectives ............................................................................................................... 3
Dual Deployment Configuration ................................................................................................................... 3
Scale Drawing ................................................................................................................................................ 5
RockSim Renderings .................................................................................................................................. 8
RasAero II .................................................................................................................................................. 8
High level list of materials ............................................................................................................................. 9
Avionics ....................................................................................................................................................... 10
Altimeter Configurations ........................................................................................................................ 11
Construction Details.................................................................................................................................... 12
Nose Cone & Auxiliary Payload Bay ........................................................................................................ 12
Forward Body .......................................................................................................................................... 14
Main Avionics Bay ................................................................................................................................... 15
Main and Aux AV Bay Soak Testing ......................................................................................................... 18
Remote test – run simulation and fire MrfPyros .................................................................................... 18
Aft Body & Tailcone ................................................................................................................................ 18
Recovery System Ground Test .................................................................................................................... 22
Applicable CTI motors ................................................................................................................................. 25
Pro75 6819 M1540-P Motor Data .......................................................................................................... 26
Preliminary Flight Profile w/CTI M1540 .................................................................................................. 27
RasAero II Analysis .................................................................................................................................. 28
Selected Motor & Flight Simulation ........................................................................................................ 28
Analysis of RasAero flight simulation data.............................................................................................. 29
Draft Pre-Flight Checklist ............................................................................................................................ 30
Flight Recap ................................................................................................................................................. 33
May 21, 2016 .......................................................................................................................................... 33
Bench Testing ...................................................................................................................................... 33
Findings ............................................................................................................................................... 33
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Flight Postmortem – October 15, 2017 L3 Attempt ................................................................................... 34
Flight data recap ..................................................................................................................................... 34
Raven 3 Flight Data ................................................................................................................................. 36
Version History............................................................................................................................................ 39
Reference Materials .................................................................................................................................... 40

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 Rocketry Warehouse Terminator 5

Project Description and Objectives

My reason for pursuing Tripoli level 3 certification includes a desire to build and safely fly larger
and heavier airframes that span the L and M range of motors. For the purpose of attaining Level
3 certification, I selected the Terminator 5 fiberglass airframe from Rocketry Warehouse. The
stock kit is 5 inches in diameter with a 75mm motor mount, stands 100” tall, and weighs 19 lbs
prior to construction.

With the primary objective of a safe flight and recovery, and a target altitude of roughly 10-12k
feet, I intend to use a CTI M1540 Imax motor. Configured for flight, it’s estimated to weigh 35
lbs, resulting in an average thrust to weight ratio of 9.8:1.

The rocket will be configured to allow either 1010 or 1515 rail buttons, allowing it to also be
flown from the high power pads on L motors.

Dual Deployment Configuration

In order to preserve space in the aft airframe for longer motors, the drogue and main parachute
will be deployed from the forward body tube and nose cone respectively. Deployment events
will be controlled by fully redundant Marsa54L altimeters w/MrfBridge boards. Nose cone main
chute deployment events will be initiated by paired Marsa MrfPyro boards mounted in an
auxiliary AV Bay attached at the nose cone. (Refer to scale drawing, avionics schematics and
layout.)

Even though the booster section is not intended to separate from the main AV Bay, an
appropriately sized recovery harness and drogue will be included as a safety measure.

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Note: Because the Marsa ‘gadgets’ are relatively new and some failure modes may not yet be
known, a Raven 3 will be implemented as a tertiary altimeter, mounted in the nose cone
auxiliary altimeter bay. In the event that neither apogee event successfully separates the
drogue payload bay, which would result in a high velocity return, the Raven 3 will discharge the
main parachute as a failsafe. Even though this increases the risk of shredded recovery gear it
reduces the risk of an uncontrolled, high velocity return. The Raven 3 will be configured to
initiate a main ejection charge at 500’ AGL, well after the primary and secondary main
parachute charges should have already fired by the Marsa54L’s. (The Raven 3 will be used as
tertiary for the main only, not the drogue.)

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Scale Drawing

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 Main
Chute
28"

Aux
Avionics Bay

(3) #4 Nylon
Shear pins

Drogue
Chute

Main Avionics 22"

Bay

(8) 8-32
stainless screws
w/ PEM nuts

100"

cg 66.5"

5"
38"

cp 80.1"

12"

3.75

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Nose Cone and Aux AV Bay Detail

10"

Charge holders

28"

32"

Main
Parachute

(3) #4 shear pins

for Main chute

(2) Marsa MrfPyro

Boards in upper AV
Bay 2"

10"
(3) Schurter
Switches for
Marsa MrfPyros
and Raven 3 5"

(3) #4 shear pins

for Drogue chute

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RockSim Renderings

RasAero II

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High level list of materials
Construction Materials:
 Rocketry Warehouse Terminator 5 kit
 West Systems Epoxy 105/205
 West Systems 404 High Density Filler
 Proline 4100 Epoxy (External Fillets)
 JB Weld high temp epoxy (for components affixed to motor mount tube)
 Aeropack RA75P Retainer
 1515 Rail buttons (1/4-20 PEM nuts; .328 dia. 21/64 drill bit)
 8-32 PEM nuts also installed to allow 1010 rail buttons on future ‘L’ flights.
 #4 Nylon screws (shear pins)

Avionics:
 Fully redundant Marsa54L altimeters, with MrfBridges and MrfPyros for wireless remote
deployment of main recovery gear from the nose cone.
 Featherweight magnetic switches to control power to Marsa54Ls.
 Shurter rotary switches for MrfPyros and Raven 3 in auxiliary nose cone AV bay.
 Shurter rotary switch for RealFlight Systems GPS-1 in main AV bay.
 Real Flight Systems GPS-1 Telemetry Tracking Module
 Batteries:
o Marsa54L: 7.4v 500 mah LiPo
o Marsa MrfPyro: Integrated batteries
o Raven 3: 3.7v 300 mah LiPo
o RFS GPS-1: 7.4v 2200 mah Lipo
 ¼ inch Grade 8 all-thread rod (tensile strength 155k psi; compared to stainless at 75k psi)

Recovery:
 Drogue: 36” TAC-1 drogue (Giant Leap) (88 fps)
 Main: 84” Fruity Chute Compact Iris (16 fps; max deployment velocity 120 fps.)
 Kevlar harnesses
o Drogue: 25’x 7/16 Kevlar, (rated 5,300) lbs; 6’ to nosecone
o Main: 25’ x 7/16 between aux AV bay and Main (rated 5,300) lbs; 6’ to nosecone

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Avionics
Altimeter Schematic
Tertiary Schurter
`
Main Optional Rotary Switch
Ignitor ` Featherweight
Raven 2
(Tertiary Altimeter)

MrfPyro MrfPyro

Schurter Primary Seconodary Schurter

Rotary Remote Remote Rotary
switch (w/integrated (w/integrated switch
battery) battery)

Redundant
Redundant
Primary
Secondary
Main
Main
Ignitor
Ignitor
Aux AV Bay
Components

Main AV Bay
Components
MrfBridge MrfBridge

Primary Secondary

Primary Secondary
Drogue Drogue
Ignitor Ignitor

Marsa54L w/ Marsa54L w/
MrfBridge MrfBridge

Primary Secondary
Altimeter Altimeter

Featherweight Featherweight
Mag Switch Mag Switch

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Altimeter Configurations
Primary Secondary Tertiary
Marsa54L Marsa54L Featherweight
Raven 3
Configuration Accel OR Baro; Accel OR Baro;
No Kalman No Kalman
Channel 1 Drogue: Apogee Drogue: Apogee not used
+1.5 sec
(Apo 1) (Apo 2)
Channel 2 Main: 500 ft

(M3)
Channel 3
Channel 4
Channel 5
Channel 6 (pyro) Main: 1,000 ft Main: 800 ft

(M1) (M2)
Channel 7 (pyro)

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 NOTE: Only the Main channel is used.

Construction Details
Nose Cone & Auxiliary Payload Bay
The nose cone coupler/ auxiliary AV Bay, containing the main chute, is retained in the
nose cone and forward airframe by means of three (3) #4 nylon shear pins each. (Refer
to shear pin table).i This allows for two separation events; one for the drogue, initiated
from the main AV Bay, and the other for the main chute, initiated by the MrfPyros
mounted in the nose cone auxiliary AV bay.

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Construction Photos

Figure 1 Preparing the Aux AV Bay switch band, test fit the switches.

Figure 2 Aux AV Bay w/ 2 sided sled.

Figure 3 Bench testing pyros and Raven 3.

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Figure 4 2 Sided Aux AV Bay, w/ 2 Marsa MrfPyros and a Featherweight Raven 3

Figure 5 Assembled Aux AV Bay

Forward Body
The forward body, containing the drogue chute simply has holes near the forward end
for #4 nylon shear pins, and near the aft end for attaching the AV Bay coupler as
described below.

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 Figure 6 Forward Body with Main AV Bay mounted.

Main Avionics Bay

The AV bay is affixed to both the forward and aft bodies by means of four (4) 8-32
stainless machine screws each, using PEM nuts embedded within the AV Bay. The AV
Bay will remain attached to both the forward and aft body tube (booster) during drogue
deployment.

According to the following specs, four (4) stainless 8-32 screws should be sufficient to
withstand recovery forces.ii

Screw Shear /lbs

Min Dia Area
Size sq ft.
8-32. 0.1248 0.04893 2,740.10

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Figure 7 Main AV bay with dual Marsa54L altimeters, using Featherweight magnetic switches.

Figure 8 Real Flight Systems GPS-1 tracking module, with batteries for all systems.

Figure 9 Close-up of GPS-1 and antennas.

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Figure 10 GPS-1 modem antenna attachment.

Figure 11 Stainless safety wire retainer

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Main and Aux AV Bay Soak Testing

First Test: All avionics were powered up in sequence and allowed to run as if on the pad for two
hours. Aux AV Bay and Main AV Bay about 24 inches from each other. GPS-1 powered down at
1:42. No adverse issues.

Distance Test: After charging all batteries, all avionics powered on in sequence. Attempted with
a distance of 25 yards between Aux and Main bays. Inconsistent results in detecting MrfPyros.
Reduced to 20 yards with no issues.

Remote test – run simulation and fire MrfPyros

At a distance of 20 yards, powered up all devices in sequence, then ran Marsa flight simulation
to test reliability of communication to MrfPyros. Apogee e-matches and Main e-matches
successfully fired as expected on both AV Bays.

Aft Body & Tailcone

Construction will be typical through-the-wall attachment of fins to the motor mount,
using reinforcing fillets on the root edges, inside the outer airframe wall, and exterior to
the airframe.

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 Figure 12 Split fins installed ensuring they are properly aligned and perpendicular with airframe.

Figure 13 Showing lower pair of PEM nuts installed, allowing for small or large rail buttons to be installed.

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Figure 14 Note: Aeropack retainer is recessed in tail cone, thereby allowing retainer cap to also act as a thrust ring, transferring
motor thrust to outer airframe.

Figure 15 After injecting internal fillets, mask and pull external fillets using Proline black epoxy.

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Figure 16 First look at the assembled airframe.

Preliminary weight w/o motor, 23.5 lbs

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Recovery System Ground Test

Deployment charges for both drogue and main were calculated to require between 1 ½ and 2
grams of BP.

Successful test using 2 grams as shown below. (Video of test may also be viewed at
https://youtu.be/Z-M9kqK2i5c )

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Applicable CTI motors
The goal is to identify a CTI M-class motor that does not require grain bonding, an altitude between 10k
and 12k feet, and that will not linger in the transonic range (800-1126 fps). [From Thrustcurve.orgiii]
Guide Burnout Burnout Max Max Apogee Max
Motor Bond? Velocity (m/s) Time (s) Altitude Acceleration Velocity (f/s) Time (s) Altitude
iv (m) (G) (ft)
Cesaroni 25.16 4.7 861.6 9.37 1012 23.58 9,996
M1101
Cesaroni Bond 36.41 2.5 548.1 19.58 1221 22.74 10,532
M2250
Cesaroni 25.86 4.7 920.4 10.22 1078 23.89 10,569
M1230
Cesaroni 32.39 3.2 678.5 15.58 1205 23.26 10,779
M1830
Cesaroni 28.62 3.5 694.3 12.99 1192 23.77 10,926
M1770
Cesaroni 22.60 5.2 989.0 8.72 1092 24.725 11,056
M1160
Cesaroni 33.75 3.0 639.0 17.47 1175 23.77 11,066
M2075
Cesaroni 29.48 3.9 852.3 14.62 1179 24.29 11,393
M1670
Cesaroni 29.68 3.6 772.2 14.14 1253 24.07 11,456
M1810
Cesaroni Bond 38.94 2.0 458.0 26.69 1382 23.29 11,479
M3100
Cesaroni 25.86 5.0 1081.8 10.39 1177 24.78 11,635
M1401
Cesaroni Bond 30.35 3.8 866.3 14.08 1242 24.19 11,641
M1675
Cesaroni 30.56 4.6 1068.4 14.47 1170 24.56 11,755
M1400
Cesaroni Bond 31.12 3.5 822.6 15.73 1273 24.44 11,981
M2080
Cesaroni Bond 35.70 4.9 1165.1 18.63 1132 24.75 11,981
M1300
Cesaroni Bond 42.15 1.8 442.0 28.44 1468 23.98 12,350
M3700
Cesaroni 30.10 4.5 1080.0 15.26 1259 24.99 12,478
M1540
Cesaroni 33.75 3.6 929.0 16.59 1409 25.08 13,153
M2045
Cesaroni 32.70 3.5 868.6 16.97 1436 25.24 13,296
M2150
Cesaroni 31.79 4.8 1267.6 14.51 1335 25.79 13,653
M1590
Cesaroni 25.24 9.0 2002.7 11.36 1044 28 13,751
M840
Cesaroni Bond 25.82 5.4 1303.5 10.37 1338 26.84 14,151
M1545
Cesaroni Bond 33.34 4.3 1242.6 15.93 1473 26.05 14,443
M2020

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 Cesaroni Bond 31.96 4.4 1384.4 17.38 1648 27.12 16,184
M2245
Pro75 6819 M1540-P Motor Data

Motor Data
Brandname Pro75 6819M1540-P Manufacturer Cesaroni Technology
Man. Designation 6819M1540-P CAR Designation 6819-M1540-P
Test Date 5/4/2009
Single- Reloadable Motor Dimensions mm 75.00 x 757.00 mm (2.95
Use/Reload/Hybrid x 29.80 in)
Loaded Weight 5906.00 g (206.71 oz) Total Impulse 6819.40 Ns (1534.37 lb-s)
Propellant Weight 3624.40 g (126.85 oz) Maximum Thrust 2328.80 N (523.98 lb)
Burnout Weight 2128.00 g (74.48 oz) Avg Thrust 1537.10 N (345.85 lb)
Delays Tested plugged ISP 191.86 s
Samples per second 1000 Burntime 4.44 s
Notes 33% M

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Preliminary Flight Profile w/CTI M1540

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RasAero II Analysis

Selected Motor & Flight Simulation

Preliminary Simulation results
M1540-IM-None

Launch conditions
 Altitude: 0.00000 Ft.
 Relative humidity: 50.000 %
 Temperature: 59.000 Deg. F
 Pressure: 29.9139 In.

Launch guide data:

 Launch guide length: 72.0000 In.
 Velocity at launch guide departure: 71.3754 ft/s
 The launch guide was cleared at : 0.198 Seconds
 User specified minimum velocity for stable flight: 43.9993 ft/s
 Minimum velocity for stable flight reached at: 27.0334 In.

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Max data values:
 Maximum acceleration:Vertical (y): 567.182 Ft./s/sHorizontal (x): 0.969
Ft./s/sMagnitude: 567.182 Ft./s/s
 Maximum velocity:Vertical (y): 1142.4891 ft/s, Horizontal (x): 21.8533 ft/s, Magnitude:
1142.5179 ft/s
 Maximum range from launch site: 2256.93068 Ft.
 Maximum altitude: 12076.71273 Ft.

Recovery system data

 P: 36" TAC-1 Drogue Deployed at : 25.762 Seconds
 Velocity at deployment: 4.6226 ft/s
 Altitude at deployment: 12076.71271 Ft.
 Range at deployment: -33.77618 Ft.
 P: 84" Fruity Chute Iris Ultra Compact Deployed at : 161.491 Seconds
 Velocity at deployment: 76.0933 ft/s
 Altitude at deployment: 999.96204 Ft.
 Range at deployment: 2256.93068 Ft.

Time data
 Time to burnout: 4.500 Sec.
 Time to apogee: 25.762 Sec.
 Optimal ejection delay: 21.262 Sec.

Landing data
 Time to landing: 269.603 Sec.
 Range at landing: 2256.93068
 Velocity at landing: Vertical: -4.9144 ft/s , Horizontal: 0.0000 ft/s , Magnitude: 4.9144 ft/s

Analysis of RasAero flight simulation data

According to RasAero, the flight will be in the transonic region at 2.1 seconds for 1.6 seconds (885’ to
1,941’), with MaxQ reached at 3.7 seconds at an altitude of 2,543 ft, resulting in 135.4 lbs of drag.

The flight will reach apogee of 12,695 ft. at 26 seconds flight time.

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Draft Pre-Flight Checklist

Before launch day

 Charge LiPo batteries, including spares.
 Charge on-board MrfPyro batteries.
 Charge RFS BaseStation 2.
 Check voltage of all batteries and label.
 Verify all altimeter settings.
 Verify GPS-1 settings & reception. Attach flash battery and save almanac (14 days).
 Measure ejection e-match resistance.
 Pre-measure ejection charges (2 gram vials) and assemble charge holders; DO NOT attach
ematches to terminal blocks.
o 2 grams primary apogee; 2.5 grams backup apogee.
 Ensure sufficient #4 nylon shear pins
 Remember to take motor ignitor and tube.

Prep Auxiliary AV Bay

 Verify MrfPyro rotary switches are OFF.
 Assemble Aux AV Bay.
 Secure charges in nose cone holders.
o 2 grams primary and backup; 2.5 grams tertiary.
 Attach nose recovery harness, load main parachute.
 Attach harness to fwd side of Aux AV Bay.
 Insert Aux AV Bay into nose cone, and insert shear pins.

Launch Day
Verify altimeters and assemble main AV Bay
 Ensure all switches OFF
 Attach altimeter batteries only
 Attach e-matches to MrfPyros
 Attach e-matches to Marsa54Ls
 Power ON MrfPyros
 Power ON both altimeters, verify MrfBridges and MrfPyros are properly detected via on-board
LCD.
 Verify beep codes. (2 rising=pyro not found; 3 rising = pyro found.)
 Verify e-match continuity as expected. (the purpose is testing the electronics) Marsa 1
beep=bad; 2 beeps=good
 Power OFF and remove e-matches.
 DOUBLE CHECK ALL SWITCHES OFF

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Verify GPS and assemble main AV bay

 IMPORTANT: Attach GPS-1 RF antenna before connecting battery & powering up.

 Verify GPS rotary switch is off (left position).

 Connect GPS battery; verify flash battery still attached.
 Power GPS-1 and verify reception.
 Power off via GPS-1 Shurter rotary switch.
 Assemble AV Bay.
 Secure safety wires on eye nuts.
 Attach deploy charges connections.

Prep forward body tube and drogue chute

 Attach harness to aft side of Aux AV Bay bulkhead (now on nose cone).
 Attach forward body tube to nose cone AV Bay coupler with shear pins
 Pack drogue and insert into forward tube, followed by remaining harness.
 Attach harness to forward AV Bay eye nut.
 Insert main AV Bay into forward bay, and attach with four (4) 8-32 stainless machine screws.

Assemble motor per instructions

 Verify torque of forward and aft closures.

Complete assembly
 Load assembled motor into airframe.
 Check fit of Aeropack retainer.
 Attach harness to motor eye bolt and body harness.
 Attach harness to aft AV bay eye nut.
 Attach aft AV Bay to aft body and affix with four (4) 8-32 stainless machine screws.
 Power up GPS-1 via screw switch and verify reception, then power off.
 Take to pad: Motor ignitor, ignitor tube, tape, magnet, small slotted screwdriver, wire cutters,
RFS GPS Basestation.

Pre-flight check
 Complete L3 form, TAP Pre-flight data form, Flight card
 TAP review
 RSO review

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  At Pad
 Load on pad
 Enable nose cone MrfPyros and Raven 3 via rotary switches
 Warning: Nose Cone Charges are now HOT
 Power up GPS-1 and verify reception
 Enable Marsa54L #1
o Verify beep codes (5, 5, 3 long, [cont. test], 3 rising=pyros found; 2 beeps = pass)
 Enable Marsa54L #2
o Verify beep codes
 Insert motor ignitor, attach leads, continuity check

Flight Events:

Time (Seconds) Event

3.7 sec Max Q
4.4 sec Burn-out
25 sec Apogee event
161 sec Main event 1000’
168 sec Backup Main 800’
172 sec Tertiary backup 500’
210 sec Landing

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Flight Recap
May 21, 2016
During assembly of the rocket, all charges were connected using ematches that had been tested,
and all electronics were powered on and tested as the rocket was being assembled at the launch
site.

After assembling the rocket, there was a lengthy wait for the away pad. When the pad was
available, the rocket was loaded and prepped for flight.

On the pad, the Featherweight Raven 3 (configured as a tertiary backup for the main) signaled
the correct codes. However, both Marsa54L altimeters’ beep codes indicated failed continuity
tests. At that point the launch was scrubbed.

After returning home, I measured voltages on all batteries, but the batteries on both MrfPyros
were discharged below an acceptable level. (Unsure, but I may have left switches on when
troubleshooting at the launch site.)

Bench Testing
Working under the assumption that the MrfPyro batteries were inadvertently left on for an
extended period prior to the flight, I tested the behavior of the MrfPyros over time, allowing the
batteries to discharge.

After recharging all batteries, both Marsa54L altimeters were tested as originally configured for
flight. All ematches were manually verified using a multimeter prior to the test. The Marsa54L’s
indicated valid continuity. Using the onboard diagnostics, the impedance of the ematches was
measured with each test.

Findings
Once the MrfPyro batteries discharged for a few hours they began to fail continuity tests. The
onboard diagnostics showed unpredictable and erroneous ematch impedance as the onboard
MrfPyro batteries discharged. The voltage was sufficient for the MrfPyros to communicate
wirelessly with the Marsa54L receivers, but the continuity checks were unreliable.

Detailed diagnostic data from all tests was forwarded to John at Marsa Systems for analysis.
After analysis, John determined that a firmware change would enable the MrfPyros to more
accurately and reliably measure the impedance of connected ematches, particularly at reduced
voltages.

After being updated, the Marsa’s, MrfBridges, and MrfPyros were re-tested. After leaving the
MrfPyros on for an extended time (replicating the scenario of an extended wait for pad
availability), the configurations were testing using onboard simulation. All ematches fired as
intended.

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Flight Postmortem – October 15, 2017 L3 Attempt

After prepping the rocket per the checklist, the rocket was loaded on the launch pad and all
electronics were enabled and passed power-up checks.
The flight was very close to the simulations, as shown in the table below. Unfortunately, the
apogee charges appeared to be insufficient to separate the airframe, and the drogue chute was
not deployed. Real-time GPS tracking indicated the rocket was in a ballistic return when the
main chute deployed at 100’, at approximately 550 fps, shredding the main chute.
Nonetheless, this slowed the descent sufficiently to save the onboard electronics, allowing all
data to be downloaded for analysis. The only damage sustained to electronics was one broken
LCD display, and a GPS receiver antenna.

Flight data recap

Peak Peak
Alt Alt Peak Peak Descent
Baro Accel Velocity Accel Velocity
SIM 12076 1142
Marsa 1 12169 12530 1060 11.15 550 avg fps
Marsa 2 12183 11355 1058 12.2
Raven 3 11983 1317
GPS-1 12377 1341 495 avg fps

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Google Earth View

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Raven 3 Flight Data

Figure 17 Zipper of fiberglass airframe

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Figure 18 Airframe damage

Figure 19 Airframe damage

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Figure 20 Closeup of airframe damage

Figure 21 Post-flight apogee charge holders; both fired.

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Version History
Version Date Details
1.0 1/15/2016 Initial version
Need to add details for Raven3 configuration.
1/22/2016 Add construction photos of Aux AV Bay.
Details for Raven 3 configuration.
1.1 1/24/2016 Photos testing Aux AV Bay
1.2 2/14/2016 Photos of forward body, and completed main AV bay.
1.3 3/6/2016 Photos of aft body and assembled airframe.
1.4 3/13/2016 Update design for Real Flight Systems GPS-1
Update to 84” main chute (17 fps)
1.5 4/30/2016 Update drogue to 36” (88 fps); Ground test results; update misc. as-built
info
1.6 5/1/2016 Changed Marsa54L settings; other minor corrections and edits
1.7 7/11/2016 Added diagnostic information for scrubbed flight.
1.8 9/29/2016 Updated checklist in preparation for 10/15 flight.
1.9 10/30/2016 Updated with L3 flight postmortem and photos.

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Reference Materials
i
Pressure in unvented airframe:
Pressure at sea level: 14.7 psi
Pressure at 12,000 ft: 9.35 psi
Differential: 5.35 psi
Area 5" rocket 19.63438 sq in
Pressure: 105.0439 psi
3 #4 Nylon shear pins: 114 psi (avg)

Shear Pin Shear Strength

https://web.archive.org/web/20110811054310/http://www.rocketmaterials.org/datastore/cord/Shear_Pins/index
.php

#2 Nylon Screws #4 Nylon Screws

# of Pins Peak Load (lbs) Peak Load (Each Pin) # of Pins Peak Load (lbs) Peak Load (Each Pin)
2 53.123 26.56 2 81.304 40.65
2 45.952 22.98 2 85.148 42.57
2 50.848 25.42 2 75.944 37.57
2 51.799 25.90 2 80.391 40.20
2 47.924 23.96 2 80.908 40.45
Avgs 49.93 24.64 80.75 40.30

3 62.637 20.88 3 119.273 39.76

3 60.569 20.19 3 110.999 37.00
3 64.395 21.47 3 99.969 33.32
3 62.413 20.80 3 113.554 37.85
3 68.760 22.92 3 116.208 38.73
3 66.643 22.21 3 121.121 40.37
3 123.689 41.23
Avgs 64.24 21.41 114.97 38.32

4 86.699 21.67 4 143.405 35.85

4 86.855 21.71 4 152.368 38.09
4 78.771 19.69 4 142.026 35.51
4 84.269 21.07 4 160.489 40.12
4 85.617 21.40 4 153.302 38.33
4 90.402 22.60 4 154.766 38.69
4 160.368 40.09
Avgs 84.44 21.36 152.38 38.21

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ii
http://www.cactus.org/~tbodine/Alarms/ScrewShear.htm
iii
http://www.thrustcurve.org/motorguide.jsp?rocket=4597
iv
http://www.pro38.com/pdfs/Pro75_notes_V1.8.pdf

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