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Category: Hobby projects

Book talk: Rocket Manual for Amateurs

Brinley, Bertrand R. Rocket Manual for Amateurs. New York: Ballantine Books, 1960. 382 pp., 75¢.

Rocket Manual for Amateurs, by US Army Captain Bertrand R. Brinley, is a remarkable book written at a very specific moment in time. After the launch of Sputnik in 1957, a craze for rocketry swept the United States, especially among teenage boys. But there was no straightforward way to build your own rocket in those days, so these boys muddled along, pillaging black powder from shotgun shells or fireworks to serve as propellant. Some of these would-be rocket engineers ended up getting badly injured by their poorly-designed rockets. But others got increasingly professional as their experiments progressed, and they ultimately built successful high-performance rockets. This period of time doesn’t have much cultural resonance now, but it is the setting of Homer Hickam’s memoir Rocket Boys (1998) and the film based on it, October Sky (1999).

I was born two generations too late for the post-Sputnik rocketry craze, but I also loved rockets in my youth. I happened upon Brinley’s Rocket Manual for Amateurs in a used bookstore in 6th grade and spent many, many hours reading parts of it over the next several years. I never did read the whole thing all the way through, though. Recently, I pulled it off the shelf on a lark and read the entire book, after not having opened it for at least two decades.

Bertrand Brinley was an Army public relations officer, the head of the First U.S. Army Amateur Rocket Program. The Army program and Rocket Manual for Amateurs were both conceived on the same premise: teenagers are going to experiment with rockets one way or another, so it’s better to teach them how to do it safely than to try to stop them. Not everyone agreed with this approach; the American Rocket Society officially condemned amateur rocket experimentation, and Brinley wrote an open letter to the society encouraging it to change its stance.

Rather than jumping right into discussing rockets, the first chapter of Rocket Manual for Amateurs explains how teenage rocket experimenters should get organized, by forming a rocket society, recruiting adult advisors (an overall sponsor and a technical advisor), and getting permission from local authorities and landowners to conduct their rocket experiments legally. Chapter 1 even includes a model constitution for a rocket society. The book next proceeds with a quick-start guide of sorts about how to build and launch simple rockets, using steel tubes or cigar canisters for thrust chambers and hand-mixing your own propellants. Subsequent chapters go into much more detail about all the major aspects of amateur rocketry, including propellants, rocket motor design, payloads, setting up a firing range, range procedure, and tracking.

When I read this book as a teenager, I was frankly awed by the scary-looking equations in its pages, especially the ones for nozzle design in the chapter about rocket motor systems. I wanted to run those calculations myself, but I never could quite summon up the courage to try. When it came to math in high school, I was a mediocre student at best. Twenty years and one engineering degree later (my math got better in college), I can now see that the calculations in the book are actually pretty simplified. Trigonometry appears in somewhat simplified form, while there is not so much as a hint of calculus or any other higher-level math.

One of the rocket-nozzle equations that intimidated me as an adolescent.

One of the rocket-nozzle equations that intimidated me as an adolescent.

Brinley writes in a conversational style, with a bit of a fatherly tone. (He was in his early forties when he wrote this book. He went on to write a series of books for children called The Mad Scientists’ Club, which I have never read but surely would have loved if I had run across them in my used bookstore rather than Rocket Manual for Amateurs.) In the discussion of simplified rocket nozzle design (a few pages before those equations that awed teenage-me ever so much), Brinley writes:

If you can’t do square roots you can multiply the diameter of the throat by 2.64 to get the diameter of the exit for a 7 to 1 area ratio, or 2.81 to get the diameter of the exit for an 8 to 1 area ratio. However, you shouldn’t be designing rockets if you can’t do square roots yet.

This piece of advice has stuck with me ever since I read the book as a teenager:

If you would be a successful organizer and ‘run a tight ship,’ as they say in the Navy, then you must learn to apply two very simple, but inviolable rules:

Never establish a rule or regulation that is not entirely necessary.

Never establish a rule or regulation which you cannot enforce, no matter how necessary you feel it is.

This advice made an impression on me as well:

It is a good rule in life never to open your mouth the first time that an idea occurs to you. Think it over for awhile and consider it from every angle. After you have thought about it for a few hours, or a few days, and it still seems to be a good idea, then it is time enough to talk it over with someone else. You can save yourself and your group a lot of embarrassment this way; and you will earn a reputation as a sober thinker, rather than a blabbermouth.

Another standout feature of the book are the illustrations, by Barbara Remington. They are clear and precise but also give the book warmth and character.

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Overall, Rocket Manual for Amateurs definitely belongs to a different time. It is hard to imagine teenagers now having the discipline or the time to organize a rocket society, meet weekly, and build metal-bodied rockets from scratch. My generation never would have had the focus for that—and we were teenagers before social media and mobile computing. The America in this book is more coherent culturally and a good deal less crowded than the one of today. The ideal amateur rocket range described in the book occupies at least 12 square miles and has permanent structures including launching pit, fueling pit, five control center, guardhouses, and observation bunkers. I don’t know where you would find that kind of land now. I wonder how many former amateur rocket ranges are now occupied by shopping malls or housing developments.

This was a fun book to revisit, and I’m glad that I finally read the whole book all the way through for the first time.

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“Simplified Soyuz” model rocket

Two years ago, I watched a Soyuz launch to the International Space Station on NASA TV. I was inspired to write a blog post about how both the Soyuz rocket and spacecraft represent at once technological continuity and change. The basis of the Soyuz rocket is the R-7 Semyorka missile, which first flew in 1957. Space launchers derived from the Semyorka have been launching satellites and spacecraft into orbit since Sputnik 1.

Back when I was in high school, I built and flew a model rocket of another Semyorka-derived space launcher, the Vostok rocket. The model was based on plans by Peter Alway, scale model rocketeer extraordinaire and author of the ever-fascinating (and now apparently back-in-print!) Rockets of the World. Alway had posted the plans on his website (now offline). The geometry of the Semyorka is pretty complex, with lots of tapered cones and tubes of different diameters. Alway simplified the geometry a little and called his plan “Simplified Vostok.”

My own Simplified Vostok was difficult to build, and it took me a couple of years to complete it. The one time I launched the rocket, it had a rough landing, and some of the boosters (made out of paper) got damaged. Years later, I put the rocket on display in my office, with the damaged parts turned toward the wall.

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My “Simplified Vostok” rocket.

Some time after I watched the 2020 Soyuz launch and wrote the blog post about it, it occurred to me that I could adapt the Simplified Vostok plans to make a Soyuz rocket, or in this case “Simplified Soyuz.” Right around this time, NASA was commemorating the twentieth anniversary of the Expedition 1 mission, the first crew rotation on the International Space Station, which launched on a Soyuz rocket on October 31, 2000. I decided that this would be a good Soyuz launch to portray in my own model.

Expedition 1 (Soyuz TM-31) rocket on its way to the launch pad in Kazakhstan. (NASA photo)

Expedition 1 (Soyuz TM-31) rocket on its way to the launch pad in Kazakhstan. (NASA photo)

Soyuz TM-31 before its erection on the launch pad. (NASA photo)

Soyuz TM-31 before its erection on the launch pad. (NASA photo)

Launch of Soyuz TM-31 on October 31, 2000.

Launch of Soyuz TM-31 on October 31, 2000. (NASA photo)

To convert the Simplified Vostok plans to Simplified Soyuz, I had to lengthen the rocket, as the Soyuz rocket has a larger upper stage than the Vostok rocket did. I also had to redesign the nose cone.

The Soyuz spacecraft has an escape tower, which is used to pull the crew cabin away from the rocket in the event of an emergency. (Mercury and Apollo spacecraft also had escape towers, as does the Orion spacecraft. Vostok had an ejection seat for the lone cosmonaut inside.) Initially, I thought that I would craft the escape tower out of dowels, but I decided instead to try using a new technology that hadn’t been available when I was building rockets twenty years earlier: 3D printing.

Using FreeCAD, I designed a nose cone with an escape tower, basing it off of data in Rockets of the World. I exported the design to an .stl file and ordered a plastic print of it from Shapeways. I ordered two copies of it, in case I messed one of them up, but this turned out not to be necessary. The printed piece was rough, so I had to putty and sand the surface multiple times until I was satisfied with the result.

Simplified Soyuz plans

Original Simplified Vostok plans by Peter Alway, with my modifications to make it Simplified Soyuz. When I made these modifications, I hadn’t yet decided that the nose would be a 3D-printed part.

Simplified Soyuz nose cone CAD model

Nose cone for Simplified Soyuz, as designed in FreeCAD.

Soyuz nose cone 3D-printed part

Simplified Soyuz nose cone from Shapeways, with its first layers of putty to make the surface smooth.

The hardest part of building Simplified Soyuz was assembling the paper boosters. Another challenging aspect of this build was adding little details made out of balsa scraps to make the model look more like the real thing. It took me a couple of tries to get the fins of the launch-abort system to look right.

Soyuz booster assembly

Assembling Soyuz boosters.

Paper Soyuz boosters

Completed boosters, all ready to paint.

Spacecraft fairing attempts

Two attempts at making the spacecraft fairing. The one on top is the one I actually used.

Working on Simplified Soyuz while watching a real Soyuz launch on NASA TV!

Working on Simplified Soyuz while watching a real Soyuz launch on NASA TV!

Painting the rocket was also a big challenge, and it took me more than a year to complete. I did most of the painting with an airbrush, which made for a very smooth finish. The final product looks far better than the Vostok model that I built in high school.

Simplified Soyuz complete

The finished product.

Semyorka boosters

The boosters of the Semyorka.

Interstage trusswork

Detail of the interstage between the second and third stages. (This is open trusswork on the real thing. My model only has one stage.)

Spacecraft fairing

Detail of the completed spacecraft fairing.

I built Simplified Soyuz to fly, but I don’t think I will launch it. Thinking back to what happened to Simplified Vostok, I don’t want to risk the same sort of damage to this rocket, at least not any time soon. Maybe later!

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