SUGAR SHOT'S P-CLASS MOTOR NOZZLE UPDATE

I finished the modifications to the Sugar Shot to Space's DSS TM-3 motor this weekend.  It was particularly tough machining through screw holes.  The open spaces created a hammering effect that subjected the tool and lathe to quite a beating.  I wonder if filling the holes with epoxy would have helped.  Once the adapter ring arrives I will make sure the two pieces fit together and that they fit the motor casing.  For now, I'm back to work on the TR-1 motor.

SUGAR SHOT'S P-CLASS MOTOR NOZZLE UPDATE

I'm making good progress on the nozzle, but it's slow going.  I'm about halfway through the biggest modification which is cutting a relief that the adapter ring will fit into.  The area that I'm cutting away has the screw holes in it and cutting through that section really hammers the tool.  The other mods should be simple by comparison.

SUGAR SHOTS TM-3 NOZZLE

I've started refurbishment/modification of the nozzle for the upcoming TM-3 test.  Having seen the force with which this nozzle bounced across the Mojave desert last year, it's in remarkable condition.  I started by cutting off the eight screws which held on the divergent extension.   The threads we so messed up that cutting them off was the easiest way to go.  The mods are pretty simple; removing some material from the shoulder to accommodate an adapter will take the most time.  I have it in the lathe now and hope to finish it this weekend. Marco clearly did a great job machining this nozzle.  I'm sure it was not an easy task and it would be awesome to finally get a solid firing with this nozzle.

TM-3 AND TR-1 MOTOR WEEKEND UPDATE

I finished the motor casing for the P-class SStS TM-3 motor this weekend.  Not surprisingly, the 6061 t-6 aluminum tube was much easier to work with than the steel pipe used for the previous DSS test motors.  I'm pleased with the casing and can't wait to see the completed motor.

I also managed to get a good start on the divergence half of my N-class TR-1 motor.  The 12L14 leaded steel I'm using for this piece is noticeably easier to work than the regular 1018 steel used for the other half of this nozzle.  Using some good quality silver and deming bits I was able to remove a lot of material quickly. Well relatively quickly any way.  I want to get this piece finished this week so I can get the two halves of this nozzle together.

SStS TM-3 MOTOR CASE UPDATE

 

 

I've got the SStS TM-1 motor case nearly finished.  The screw hole locations are all indexed and the ends trued up so all that is left is to drill them out and a little polishing.

SStS TM-3 MOTOR CASING

I started on the TM-3 motor tube this morning.  It absolutely dwarfs my lathe, but being aluminum instead of steel it's much easier to work with than the previous DSS motor cases that I've worked on. I only need to index the retaining screw locations and true the ends.   I should be able to finish this tonight, then I'll get to work on the other half of the TR-1 nozzle.  With approximately 90 lbs of propellant this motor should produce a total impulse that fits it into a P-Class designation.

TR-1 ROCKET UPDATE

 

 

I finished all  of the lathe operations for the nozzle ring.  When I took it off the lathe I was struck by how heavy it was.   It doesn't really matter for a static test, but I decided to go back in and remove a bit of the excess material.  The amount of material that was removed (drawing above) reduced the parts weight by nearly 30%.  It will also make it easier to drill and tap the twelve screw hole locations as they are no longer blind holes.  There are still a few areas I can pare down but I'll hold off for now.
I'm going to take a quick break from the TR-1 motor and work on the SStS TM-3 motor casing which seems to be coming together quite quickly.  This is a pretty large O or P-class motor which is about as big a "Sugar" motor as I've ever heard of.  It shouldn't take me long to finish work on the casing and then I'll get back to work on the TR-1 motor.

SStS MOTOR CASING (DSS TM-3)

The aluminum tube for the DSS-TM-3 SStS motor arrived yesterday.  I'm just indexing/drilling the screw holes so not much work for me.  DSS TM-3 motor?  OK, it's getting tough to keep track of all the motors as there are more than a few in varies stages of construction and testing.  The motor is a single burn (half of the dual phase concept) that is intended to serve as a flight motor for the avionics package once successfully tested.  The design calls for approximately 90 lbs (41 Kg) of propellant.  Hopefully that flight will occur later this year.  As always, check the weekly reports  on the Sugar shot to Space site for more detailed information.

SUGAR SHOT TO SPACE SUCCESSFUL FIRING

The Sugar shot to Space project had a much needed successful firing this past weekend.  After the spectacular CATO of the impressive DoubleSShot motor nearly one year ago there was a lot of discussion and investigation into what exactly happened and why.  This test represents the first in a series that will lead SStS to the successful firing of one of the largest amateur motors of all time.  Certainly the largest "Sugar" motor of all time.
Congratulations to Rick Maschek, Paul Avery, and Richard Nakka for their dedication and perseverance, as well as the many other numerous volunteers that have contributed to the project.

SStS, CSD UPDATE



Chamber Separation Disk (CSD) in the Mid-Bulkhead

I completed the modifications to the MBH ,CSD, and plug recently.  The entire DSS TM-1-2 test motor is now with another project member undergoing hydrostatic testing. There seems to be a lot of mixed feelings about this approach, I'm just hoping it works.  Hopefully the testing goes well and we can get to a test firing soon. 

SStS Motor Work Update

I've nearly completed the work on the MidBulkHead modifications, all I have left to do is to countersink the 24 holes on the outside edge.  This draft of the motor design shows how the CSD or disk is held by the MBH.

Sugar Shot motor work

I've begun work on modifying some existing hardware for a new SStS motor. This design will incorporate a new non-pyrotechnic device to separate the two motor chambers.  In theory the Chamber Separator Disk has a number of benefits over the pyrotechnic "plug".  This document explains the concept and you can see some of the analysis  that Ben Brockert has been working on here.  Pretty simple in theory.  This newest motor will also feature a return to the Bates grain configuration.  For more info on this motor and other recent updates, please check the Sugar Shot weekly activity reports located at the top of this page.

This is the modified MidBulkhead showing the area that the CSD will be retained.

I've begun indexing the new screw locations and will then have to drill and tap them before moving to the next task which is modify the existing motor casing.

SStS Test Parts Finished

I finished the test parts that I was working on and Rick picked them up yesterday afternoon.  He and Paul were going attempt the first test this weekend.  I was scrambling to get the parts done in time for this weekend, the steel bulkhead took a bit more time than anticipated, but hopefully the parts serve their purpose well. 
Here I'm tapping the steel bulkhead:

I was starting the tap in the v-block on the drill press to get it started straight then laying it flat to get a good enough grip on it to turn the tap.  The whole process of tapping the bulkheads took longer than I was expecting, but when you're tapping or threading it's definitely best not to rush.

Here are the finished parts:

SStS Machining

I'm currently trying to finish up a test set-up for the SStS project that will allow us to test a single grain segment with the star core that we've used for the last two motor firings.  It's simply a short section of the casing material with two end closures, one made of Aluminum and the other of steel.   Looks roughly like this:

I used the new center drill indexing the steel bulkhead and the difference was immediately noticeable.  Don't use dull tools kids!  Anyway, after realizing what a difference it made I decided that i needed to stock up on the # 1 size center drills. I managed to find a set of four # 1 center drills on Ebay.  I paid about what I did for the set from Harbor Freight, so a great deal!

Here is a shot that shows the bulkhead after I indexed it.  You can see the Dremel set-up in the tool holder and the indexing holes on the main gear of the lathe.  You can also see the indexing pin in the casting between the back of the chuck and the gear.

Here are a couple of shots showing the machining progression on this piece.  This is the first time in a while that I've done something this larger using 1018 steel and it's definitely slower that using 12L14 steel. 

Metal Purchase

I picked up some metal from Industrial Metal Supply before work yesterday. I got some 7" diameter 6061 and 1018 for a test motor I'm building for SStS and some 5" diameter stock for the TR-1 motor.

First Launch

I was out at the FAR site helping out with a SStS static firing and took my son along.  It was his first time to the site and I think he loved it.  I certainly did.  I had a lot of fun watching him explore the area.  He scoured the facility looking for "treasure" at one point I looked in the back of the van and found a pile of this treasure consisting of a broken cinder block, a one inch iron rod, half a dozen rocks (one of which was cool enough that we actually brought it home), and various nuts, bolts, washers, and pieces of scrap metal.  We saw a couple of launches and  a few static test, all in all a good day.

Souvenirs found on one of the Lunar Lander Challenge pads

Guarding the SStS motor prior to testing

Running for cover

Boiler Plate Motor Parts

I did some simple modifications to the SStS DDS BPS Motor in anticipation of an upcoming firing.  This is a nice looking motor and I can't wait for the firing...should be cool!  Here is a photo of one of the parts in the lathe and the same part being test fitted in the motor casing.

Motor Casing complete

Completed Motor casing for SStS motor test.

Casing continued...

The new casing for the DDS boilerplate motor is nearly complete, just a little more sanding on the bulkhead end (on the right in the photo), and it's ready to go.

SStS casing part three

Unfortunately the existing casing for the latest motor, a single-burn boiler plate motor, was accidentally damaged prior to testing, so I'm fabricating a new one.  Nothing new; cut to length, true ends, drill, drill, drill...
Hoping to make it to the firing and take lots of pics.