L2 Rocket "Redshift"

Background

After earning my Level 1 certification, I wanted to advance further into the world of high-power rocketry and earn my Level 2 certification. This time, I wanted to build a fiberglass aiframe and incorporate avionics into my nose cone, including a video camera to record onboard video during the launch. I also wanted to fly much faster than my Level 1 rocket, and with this in mind, I decided to name it "Redshift".

Design and Simulation

I used a simulation software called OpenRocket to simulate the rocket's flight performance and design the fins. I used a motor on the less powerful end of the L2 range, but still wanted a fast rocket, so I used a smaller 46mm aiframe to achieve an almost supersonic velocity. Being a smaller airframe, it required large fins to retain stability. To allow the airframe to withstand the forces it would experience during flight, I fabricated a custom 5-layer fiberglass laminate airframe to gain experience working with composites. The final result was a flight to 4,793ft with a maximum velocity of Mach 0.858 and stability of 2.99 calibers.

Fin Layup

Fin Tacking

First, I tacked the fins onto a thin cardboard tube using superglue and a 3D printed alignment jig

Epoxy Fillets

After the superglue set, I used a silica-thickened epoxy to create smooth fillets between the aiframe and the fins

Fiberglass Layup

After the fillets set overnight, I applied 5 layers of fiberglass to each side of the fins, saturating the laminate with epoxy during the process

Airframe Layup

After the epoxy on the fins set, I cut a long rectangular strip of fiberglass and wrapped it around the airframe five times, coating it in epoxy as I turned. Once set, this formed the length of the airframe

Nose Cone Fabrication

My nose cone needed a custom hole for the video camera to record the rocket's surroundings, so I needed to fabricate it myself. I 3D printed an ogive nose cone out of PETG and coated it with 2 layers of epoxy to increase its strength and prevent fractures on the surface.

Nose Cone Avionics Bay

The avionics bay is the most complex part of this rocket. It houses a Runcam Split HD video camera and its control board, a featherweight GPS tracker, and each of their respective batteries within a 35mm diameter.

It slots into the shoulder of the nose cone using radial bolts and includes a clocking or "poke-a-yoke" feature to ensure that the camera is correctly aligned with the camera hole in the nose cone. The nose cone was also printed with a small hole in the shoulder, allowing the camera to be switched on while the rocket is on the launch pad. This saves battery and prevents the camera from overheating before launch.

Sanding and Painting

After sanding the airframe and nose cone to reduce the surface drag of the airframe, I coated each with 2 layers of primer and spray-painted a red to black gradient along the length of the rocket.

Before I launch, I plan to use a stencil to paint the name "Redshift" along the length of the rocket.

Redshift Ejection Test.MP4

Ejection Testing

I conducted an ejection test with a small black powder charge to ensure that the motor's ejection charge was powerful enough to eject the parachute. The test was a success, and the rocket is now ready to fly! I plan to launch it in November 2025

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