Contributed by Peter Stanley(Contributed - by Peter Stanley - 07/28/09)
The Starhawk kit contained one 0.787" body tube, plastic nose cone, plastic 4-fin fin can, a streamer, Kevlar® cord, elastic cord, an 18mm motor tube, engine block, and engine hook. The body tube was slightly bigger than a BT-20, which made a perfect fit for sliding over an 18mm motor mount tube.
For the first version (damaged after first flight) of the Starhawk booster, I inverted the fin can, left out the recovery system and nose cone, and cut the body tube down to 3.75 inches. I determined where the gap would be between the booster motor block and bottom of the sustainer motor. I used a large needle to poke holes along this gap around the circumference of the booster tube.
The top of the booster tube slid over the bottom of the sustainer motor tube.
After the first flight, the Starhawk booster was damaged. It was mostly burned just above the engine block. The remaining piece had a crease at the point of the gap holes. I rebuilt that part with some of the leftover Starhawk body tube. I reinforced it with another piece which was slit lengthwise and covered the tube like a sleeve. I painted the outside sleeve with 30 minute epoxy and coated the inside with thin CA. This added strength and made the tube more burn resistant. I also made only two vent holes instead of several.
After rebuilding, reinforcing the booster, and adding some nose weight, I tried again. The second flight was powered with a B6-0 and B6-4. Everything worked great, and the booster wasn't damaged. The third flight was on a C6-0 to an A8-3. This flight was also perfect.
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