Mercury Joe: Semi-scale flying GI Joe Redstone Rocket

 by JamieClay
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This project was inspired 40 years ago when I got a GI Joe Mercury Capsule for my birthday. I always imagined it flying (even orbiting) and it kept me out of my parent's hair for days on end. Fast-forward to the mid 90s when the GI Joe Capsules are re-issued by Toys-R-Us -- naturally I picked up one (well 3). After the popularity and success of the Gumby flights I simply had to look to the shelf above my workstation to be inspired for my next big project. When I found a tube that was 9.25" (the exact diameter of the Capsule base), this project was set into motion.

A LOT of this project was engineered on the fly and by no means reflects the best way to approach the tasks described.  It's just how I did it and you're welcome to make changes any way that suit your engineering skills.

I offer this in hope  that this 'instructable' will inspire others to build and fly similar projects.

 
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Step 1: Preamble

Flight Plan_revized.jpg
To send a full GI Joe capsule aloft (with Astronaut), have the capsule free-fall and deploy its recovery system safely. The entire flight will be recorded by three (to 5) different on-board video systems.

This ISN'T a scale project; the "Mercury Booster" is a little thicker than the real thing. The "Mercury" capsule is built from the GI Joe unit, is under scale as well.

The big challenge of this project is to perfect a system that allows the capsule to free-fall to a safe altitude before deploying its parachutes. Technically this is no more than a dual deployment flight, but the added complication of extracting the tower so the capsule can free-fall is anything but simple.

At apogee the capsule (with tower) will decouple from the booster.

The capsule has a deployment bag attached to the heat shield which will pull out the pilot chute for the booster.

The decoupling activates an ejection charge timer inside the tower, allowing for the capsule and tower to drift away from the booster which will be unfurling its main chute.

Once the tower charge has fired and its chute has inflated, the weight of the capsule causes it to fall free off the tower base.

The capsule free-falls to about 1500' before deploying a pilot and main chute combination.

With all going to plan, video of the flight is captured from the booster, looking up and down,  the Tower, looking down and the capsule, both interior and an additional view down. 
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angeloskii says: Jan 25, 2013. 9:34 PM
that is so cool man. congratulations. may your parents be proud of you.
bjc4073 says: Aug 8, 2012. 5:59 AM
How much does your rocket cost and do you have full construction instructions somewhere? Great project.
the_burrito_master says: Apr 12, 2012. 12:30 PM
Toilet paper tubes, it ain't rocket science fellas ;)
Aron313 says: Mar 9, 2012. 6:20 PM
This should of won 1st!
rimar2000 says: Oct 1, 2011. 6:05 PM
Great work!! Congratulations.
itsjustdoc says: Sep 28, 2011. 7:33 PM
So. Gorram.Cool.
SurfRW says: Aug 15, 2011. 3:30 PM
This is amazing :O
Iwantbigboom says: Aug 12, 2011. 11:01 AM
wasnt your rocket in ldrs (large dangerous rocket ships) or was that somebody elses mercury joe
JamieClay (author) in reply to IwantbigboomAug 12, 2011. 11:26 AM
Last year? I think it was Mark Hayes' of ROC. He has one that is about the same size.

http://www.youtube.com/watch?v=pqhvKsFGTtk
Iwantbigboom in reply to JamieClayAug 12, 2011. 12:09 PM
no I mean the one in 2009
JamieClay (author) in reply to IwantbigboomAug 12, 2011. 2:26 PM
Still not this one. It's never flown at an LDRS -- there have been a number of other large Mercury Redstone projects but only one "Mercury Joe". :)
profpat says: Jul 15, 2011. 7:21 PM
nice project!
ATTILAtheHUNgry says: Jul 14, 2011. 5:33 PM
Awesome!
shobley says: Jul 14, 2011. 7:17 AM
This is amazing stuff.. well done.

Can I be the first to say "SPAAAAAAAAAAAAAACE!!!!"

[Portal 2] :-)
JamieClay (author) in reply to shobleyJul 14, 2011. 2:51 PM
HA! If someone sold a Portal Space Sphere, I would be very tempted to fly it as part of the payload!

I finished that game in less time than I would like to admit.
venecha says: Jul 14, 2011. 12:46 PM
This is awesome! Thank you for taking the time to put this together!

Taking Shobley's idea a bit further though...it would be fun to mix the personality core screeching 'SPAAAAAAACE' to go off at time of launch *grin*. I might have to look into doing something like this and adding it in.
JamieClay (author) in reply to venechaJul 14, 2011. 2:49 PM
I've been meaning to add a system that does audio reports based on different launch events. One guy I fly with has the voice reporting all activity on board the rocket in real time.
seamster says: Jul 10, 2011. 11:00 AM
This is really awesome! I love seeing things like this posted here. I'm still just an estes rocketeer, but this makes me want to join the big leagues. Wow!
JamieClay (author) in reply to seamsterJul 10, 2011. 12:54 PM
I totally understand - you should find a high power rocketry club in your area and see these things fly first hand. It'll get your blood going!!
lockpick in reply to JamieClayJul 14, 2011. 12:13 PM
Is there an ave limit on high powered rocketry?
Great rocket and ible by the way... I have always liked scaled rockets.
JamieClay (author) in reply to lockpickJul 14, 2011. 2:48 PM
The Age limit for high power is different depending on the club you choose to join and I'm not up to speed on those regulations but finding a local club and meeting the people there will give you a better idea as to what's available for you in your area.
Dead-Portalist says: Jul 14, 2011. 1:14 PM
I remember when I made a rocket from scratch using a toilet paper tube, cardboard, a straw, and a plastic bag. Best rocket I've ever flown.
askjerry says: Jul 14, 2011. 10:07 AM
Nicely done!

I really appreciate the detail you put into that... shows off the sport very well... and the video was outstanding!

Jerry
TRA 5787
66tbird says: Jul 14, 2011. 7:41 AM
Very nice build. Sure bring back memories.
Matrix-technician says: Jul 12, 2011. 3:19 PM
Wow! This is an amazing build, I have been involed in model rocketry since I could pick up a bottle of glue and a xacto knife but i've stuck closely to scale model engeneering. I seem to have trouble when i build out of scale.
tinker234 says: Jul 11, 2011. 7:02 AM
wow hey where can i find a mercuy joe set
JamieClay (author) in reply to tinker234Jul 11, 2011. 9:54 AM
I added an additional page that outlines where you can find the parts to make this.

I was approached to make this a kit but that was a while ago and nothing came of it. However, there ARE large Mercury Redstone rocket kits out there.

I'll see if I can't collect a few links and post them to the last page.
tinker234 in reply to JamieClayJul 11, 2011. 10:32 AM
ok i looked i found aone but i like yours better
JCoffey says: Jul 11, 2011. 7:28 AM
Beautifully built! What motor are you tossing her up with? Have you braved a cluster yet?
JamieClay (author) in reply to JCoffeyJul 11, 2011. 9:50 AM
I've flown this particular version (I rebuilt it once from the ground up) on an AMW L1300bb, CTI L730 and an Aerotech M1315.

I keep meaning to fly it as a cluster, I gave myself that option, but between the additional cost and complexity, I've not done it (yet).
Kaptain Kool says: Jul 10, 2011. 6:31 PM
Great detail on the rocket! I love it!
kelseymh says: Jul 10, 2011. 2:21 PM
This is an amazing Instructable, and I'm quite impressed at the level of detail you provide. Thank you for putting it together for the rest of the community!
DELETED_hkopfs9a says: Jul 10, 2011. 5:58 AM
(removed by author or community request)
JamieClay (author) in reply to DELETED_hkopfs9aJul 10, 2011. 7:48 AM
Is there no way to flag a spam comment? There should be.
Kiteman in reply to JamieClayJul 10, 2011. 8:01 AM
See where it says "flag" in the bottom corner?
JamieClay (author) in reply to KitemanJul 10, 2011. 9:03 AM
The original one said "Feature Comment Flag" and didn't offer the 'flag[delete]' option.

I see now that the message has been deleted "(removed by author or community request)" - but I didn't delete it.

I wonder if the 'flag[delete]' option, that shows up for regular messages isn't showing up in Chrome for the root message.

Interesting - anyway thanks for the reply!
kelseymh in reply to JamieClayJul 10, 2011. 2:18 PM
On a side note, the "[delete]" only appears for your own comments, or for all comments on your Orangeboard.

You're quite right (below) that the current UI makes it really non-obvious that "flag" is separate from "Feature".
Kiteman in reply to JamieClayJul 10, 2011. 10:18 AM
It's gone because the Admins have been chasing down a particular spambot.

You should be able to see a flag button on most comments (see picture) - if you can't, that may be a Chrome issue. Lithium Rain says that the non-google version ("Chromium") is better.
screen shot flag button.jpg
JamieClay (author) in reply to KitemanJul 10, 2011. 12:59 PM
You know what? It's there but the UI design made me think it was a part of the "Featured Comment" function. I didn't realize that the word flag there was a separate function.

The UI designers should make Flag a button like Reply.

Thanks.
mikeasaurus says: Jul 9, 2011. 9:41 PM
This is amazing, great work documenting and experimenting!
Would like to know more on your payload recovery methods? (tracking, logging, line-of-sight, other?)

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