With my level-3 certification attempt looming, one detail of the launch (the rod or rail) had not been finalized.

When I became aware of the new Xtreme Rail by Payload Specilities, the decision to purchase the heavy duty system was an easy one. Not only would I be able to use the rail system for a rocket considerabily larger than my projected 55 pound project, I would be able to use a single six foot section of the rail, and launch any of my small and medium sized rockets.

Figure 1: Components of Xtreme Rail System

The components of the Xtreme Rail system (figure-1) are tailored to your needs.

I decided two six foot rail sections would allow me to use the system for any size high power rocket.

Gene Nowaczyk of Payload Specialties suggested a heavy duty pad attachment (the blue section in (figure-1).

I also purchased the rail joiner assembly and two pair of rail quide assemblies.

Figure 2: Marking the launch side of the rail

The package was the longest I have ever received, and arrived quickly and in fine condition. I wasn't sure what to expect when I opened the package and I wasn't disapointed. The hardware, joiner assembly, and pad mount are all quality and heavy duty components.

No instructions were included with the rail; although it was not difficult to figure out how the parts fit together, a few paragraphs of information would be welcome.

Figure 3: Rail guide comparison

The rail has the same slot on all four sides. I wanted to make sure I always used the same side for launching, and the other sides are needed for the pad attachment and joiner assembly; the hardware will undoubtedly deposit small nicks in the slot which could hinder the gliding action of a launch.

I sprayed red paint (figure-2) to identify the slot which will never have hardware inserted.

The rail quides (figure-3) are much larger than standard rail guides. I would not use the small standard system for a rocket over about 30 pounds.

Figure 4: Guide installed on exsisting rocket

Figure 5: guide mount inside airframe

With the Extreme system, I would feel comfortable with a rocket aproaching 100 pounds. The hardware with the guides includes a stainless machine screw and an insert.

For installing the guides on a new rocket, I would epoxy small plywood blocks with blind nuts inside the airframe tube (figure-5). For exsisting rockets, I would carefully drill holes trying to find the center of your plywood centering rings, and use a flat head wood screw to install the guide, (figure-4).

In either case, I would place a washer between the guide and airframe. I did not like the results when I tried the inserts that came with the guides.

Figure 6: On the six foor rail

Figure 7: Reverse View on rail

I found them to be difficult to install straight, and when I tried to align them, they cracked.

I decided the first launch would use only one six foot rail section.

I made a second rail mount with a 3/4" stud so I could use the shorter version of the rail on any size high power pad (Figures 6 and 7).

We placed the Vaughn Brothers 5.5" Wild Thing on the rail and it slid off the bottom.

A standoff solved that problem, however I plan to fabricate an adjustable standoff for future launches.

The Wild Thing seemed to glide smoothy on the rail, so we finished our pre-launch duties, and waited.

As the I-211 roared to life, the rocket exited the rail smoothly and continued in route to a perfect boost.

Two Econo-Jet G-35's were set to be airstarted at about the time the I-211 burned out.

The recovery system performed flawlessly, and the rocket landed nearby.

We discovered one of the G-35's had CATO'ed and damaged the motor mounts, however the first launch using the Xtreme rail had been a success.

Figure 8: Heavy duty rail coupler

The second launch planned for the day would require the 12 foot coupled version of the rail (figure-8).

The two six foot rail sections are joined with the three plates as shown. One rail section has a pin to aid in the allignment. The assembled rail appears to be very sturdy.

I was ready to launch my Extended 7.5" 28 pound Rocket R&D Skyraider off the coupled rail, but there was not a pad at the launch suitable for the massive rail.

The problem was with the pad atachment section; many pads are capable of rods up to 7/8" diameter with at least 8" of rod inserted into the pad. My attachment (figure-1, blue section) has a 1" rod which is only about 6" long. The 12 foot rail debut would have to be at a future launch.

Figure 9: Modified double ended pad mount

My solution to the problem was very simple. I welded a 7/8" rod at the other end of the pad attachment (Figure 9), and I made sure over 8" would be exposed. When ordering an Xtreme Rail, I would suggest requesting similar pad attachment from Payload Specialists.

Figure 10: Payload Speciaties Launch Trailer at LDRS

Figure 11: My new Launch Trailer

Figure 12: Firebird lifts of on L-1500 at LDRS

I met Larry at the Away Cells for the test launch of my Level-3 Firebird on an L-1500 Blue Thunder motor. Larry easily positioned the trailer and extended the levelers.

Sliding the 56 pound rocket onto the rail was an easy task, and the electronics hatch was right at eye level before the rocket was raised to the launch position.

When vertical, Larry was able to adjust the three levelers to adjust the launch angle. Larry highly suggests the use of a Teflon style lubrecant on the rail / rail guide for an even smoother launch.

The Firebird launch off the trailer mounted Xtreme Rail went flawlessly (figure-12). Why was using the trailer an expensive mistake?

I liked the Xtreme Rail / trailer combo so much, I built one for myself (figure-11), and successfully certified level-3 two weeks later at Bong in Wisconsin.  The Xtreme Rail is a well engineered quality system which I highly recommend for large rocket projects.

Payload Specialties

http://www.planetkc.com/rocketman/rail.html