Rocket Launch Rig for Science Fair Project

This is a rocket launch rig that is made for the StratoLauncher IV Deluxe. The purpose of this Instructable is to be a part of a science fair project. This will show all of the steps for constructing the launch rig mentioned in the paper.

Tools:

Drill

#1 and #2 Phillips Screwdriver

Sandpaper

Countersink Bit

3/32" Self-Centering Bit

Assorted Hex Keys

Measuring Tape

Automatic Centering Punch

Rubber Mallet

Materials:

2 2'x4'x3/4" Sheets of Plywood

1 StratoLauncher IV Deluxe

1 StratoRail

4 Tent Stakes

2 1.5"x12" Continuous Hinges

4 2" Zinc Plated Light Strap Hinges

3 10s 4-Hole Vertical Inside Corner Gussets for Aluminum Extrusion

1 10s Triple Econ T-Nut for Aluminum Extrusion

6 1/4"-20x1" Machine Screws

6 1/4"-20 Zinc Plated Steel Wood Insert Nuts

1 1/4"-20x1" Allen Drive Countersunk Cap Screw

******Some materials are NOT listed in the image; likewise, some materials shown in Image are NOT used in the project

Sand the edges of the plywood. Then, attach the two long hinges to one of the boards at the edges. Drill holes using a self-centering bit, then use a hand screwdriver to screw the included screws in. Align the other board and repeat the attaching. Then, attach each of the four short hinges to each edge, where there is one hole sticking off the edge. Only screw on one side of the hinge so the hinges can still bend.

Use the parts shown to attach the brackets onto the extruded aluminum. The flat, black screws should be lower than the thicker-headed silver ones. Then, place the invisible connector on the base of the aluminum with the brackets, and attach the shorter aluminum T channel to the invisible connector so it is flush with the brackets. **In the last picture, only the invisible connector and short aluminum T channel are needed during this step.

Place the extruded aluminum over the center of the board, and using a pencil, mark where all of the holes should go. Also include a hole marking for the short aluminum T channel near the bottom. Then, drill all of the holes with a drill bit the size needed for the threaded inserts. Then, screw the threaded inserts in through the back.

Screw the launch rail onto the plywood using 1"x1/4-20 machine screws inside of the threaded inserts. Then, insert a T nut into the short aluminum and screw in another machine screw through the back of the board in the previously drilled hole.

Screw the countersunk screw into the flat aluminum piece and the bottle launcher. Then, screw a screw through the other hole on that same bracket and into the black insert which is inside the aluminum extrusion. Finally, screw in the last screw to lock the bracket in place.