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There are many types of fireworks, where one of the most common in firework displays is the aerial shell. The aerial shell is used in fireworks displays, and can be either a round or a cylindrical shape. These aerial shells are loaded into tubes, called "mortars." Once lit, the aerial shell will fly into the air and once the aerial shell is at the higest point (apogee), it will explode and shoot pyrotechnic stars in all directions.
In this instructable I will be talking about the procedure of assembling a round aerial shell.
Note: I do NOT recommend the average person to try this! This will be illegal to do without licensence in many cases, it is on your own response wether you do this legally or not.
When working with fireworks it is very important to use proper safety gear while making. It is recommended to wear faceshield or safety goggles during the making. While making the shell, one should do it away from heat souces, such as candles, cigarettes, stoves etc.
If I somehow throw around with a lot of foreign words or have any questions, feel free to ask me.
First, let's see what a typical round aerial shell looks like:
In this instructable I will be talking about the procedure of assembling a round aerial shell.
Note: I do NOT recommend the average person to try this! This will be illegal to do without licensence in many cases, it is on your own response wether you do this legally or not.
When working with fireworks it is very important to use proper safety gear while making. It is recommended to wear faceshield or safety goggles during the making. While making the shell, one should do it away from heat souces, such as candles, cigarettes, stoves etc.
If I somehow throw around with a lot of foreign words or have any questions, feel free to ask me.
First, let's see what a typical round aerial shell looks like:
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Signing UpStep 1Shell parts
Let's start making the aerial shell (from now on it will be mentioned as 'shell')
Shell hemispheres
You will need two 3" paper hemispheres to make this shell. Note that the hemispheres themself are actually not 3", but smaller, since there must be room for pasting and quick match to make the shell fit in the 3" mortar tube.
Stars
A batch of 75 grams of 10 mm pumped "Tiger tail" stars were made for this shell, however only 70 grams were used. Remember always to make more than you need. It's better to have a bit more, than be needing. The stars were primed in meal black powder to ensure ignition. Since Tiger tail stars ignite easy, you might find that this might be unnecessary. If a 'rising comet' is desired, a 20 mm or 3/4" comet is pumped with the compostion. Make sure that the comet has a burn time equal to the time fuse or spolette (3 seconds).
Tiger tail stars:
Potassium nitrate..................44
Charcoal (Pine airfloat)........44
Sulphur....................................6
SGRS or Dextrin.....................6
Chemicals can be obtained at:
Skylighter.com
Bursting charge
'Meal coated rice hulls' was used in this shell.
Time fuse
A 'spolette' is a small tube, where black powder is confined in it. This will act as a time fuse, however one can also buy time fuse from such sites as:
Skylighter.com
Pasting
30-40 lbs kraft paper in ~70x15 mm strips are used for pasting the shell using the 3-strip pasting method. If another pasting method is desired, the strips might have to be longer or wider. A glue is needed to paste the strips to the shell. Wheat paste is a cheap solution that works well.
Find out how to make it at a tutorial I made:
Wheat paste tutorial
Wood glue thinned with water can be used, however it is much more expensive.
Lift charge
A lift charge is needed to shoot the shell out of the mortar. Approximately 15 grams of good granulated or corned black powder works well. More or less might be used depending on the quality.
Ignition
For igniting the shell either a piece of visco fuse and quick match or shoothing-wire and an e-match can be used. In this tutorial a piece of shooting wire and e-match was used. Note with this way you will need a power supply, and that you can not light the shell with a lighter
Other
You will also need lifting cup, paper tape, scissors, drill, "gummed paper tape" or kraft paper, tissue paper, brush, hot melt glue gun, cotton twine and string.
Shell hemispheres
You will need two 3" paper hemispheres to make this shell. Note that the hemispheres themself are actually not 3", but smaller, since there must be room for pasting and quick match to make the shell fit in the 3" mortar tube.
Stars
A batch of 75 grams of 10 mm pumped "Tiger tail" stars were made for this shell, however only 70 grams were used. Remember always to make more than you need. It's better to have a bit more, than be needing. The stars were primed in meal black powder to ensure ignition. Since Tiger tail stars ignite easy, you might find that this might be unnecessary. If a 'rising comet' is desired, a 20 mm or 3/4" comet is pumped with the compostion. Make sure that the comet has a burn time equal to the time fuse or spolette (3 seconds).
Tiger tail stars:
Potassium nitrate..................44
Charcoal (Pine airfloat)........44
Sulphur....................................6
SGRS or Dextrin.....................6
Chemicals can be obtained at:
Skylighter.com
Bursting charge
'Meal coated rice hulls' was used in this shell.
Time fuse
A 'spolette' is a small tube, where black powder is confined in it. This will act as a time fuse, however one can also buy time fuse from such sites as:
Skylighter.com
Pasting
30-40 lbs kraft paper in ~70x15 mm strips are used for pasting the shell using the 3-strip pasting method. If another pasting method is desired, the strips might have to be longer or wider. A glue is needed to paste the strips to the shell. Wheat paste is a cheap solution that works well.
Find out how to make it at a tutorial I made:
Wheat paste tutorial
Wood glue thinned with water can be used, however it is much more expensive.
Lift charge
A lift charge is needed to shoot the shell out of the mortar. Approximately 15 grams of good granulated or corned black powder works well. More or less might be used depending on the quality.
Ignition
For igniting the shell either a piece of visco fuse and quick match or shoothing-wire and an e-match can be used. In this tutorial a piece of shooting wire and e-match was used. Note with this way you will need a power supply, and that you can not light the shell with a lighter
Other
You will also need lifting cup, paper tape, scissors, drill, "gummed paper tape" or kraft paper, tissue paper, brush, hot melt glue gun, cotton twine and string.
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That is the biggest risk when working w/ pyro like this, because it is very hard to control, and will ignite very easily. Keep the ventilation up and the air damp. Ground yourself to the area, and DO NOT sit in a rolling chair.
Shell making enterprises in the US can't use nails in the construction of their wooden work tables, and use a fully sealed, and triple grounded electrical system. Every building has a copper plate which is grounded, which everyone touches on their way in and out of the building. Same thing on the storage magazines. Also have a ground chain and spike on the trailers, which get grounded at the site...
Seriously, static sucks...
Also, read NFPA 1123. Pretty much the gold standard on this.
Pyro certification can be had by passing the PGI exam, our regulating body. www.pgi.org