Rocket Launch Rail

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This is a project I've been wanting to do for some time, build a true launch rail so I can launch my rockets without any launch lugs, buttons or guides. I guess the biggest reason I haven't done it to date is the cost, it can get expensive very quickly if I built it the way I really want it, that is, all aluminum frame with stainless steel rails. So I decided to build it on a budget, using steel conduit for the rails and wood for the frame. It should work just as well, but it will be bulkier and heavier, and will be prone to corrosion from the motor exhaust.

The basic idea is to have a 2'x2' plywood base, the four EMT rails will bolt through the bottom of the plywood into the bottom of the EMT. Another 2'x2' piece of plywood will form the upper support for the rails at a height of 8'. A wood frame-work will support the structure from the outside. At the moment I'm planning on using an old boat trailer to haul the rail on, I may even mount it to the trailer for quick set up.

This certainly isn't going to be something you throw in your trunk and take to a launch, but that's not a real high priority of mine. It sure won't be pretty either, but it should be functional, and that's the important thing.

I started by finding the center of the plywood, then drew a 16" diameter circle. I drilled out 7/8" holes for the EMT to rest against for moving and storage. This is, of course, the upper plywood. This will accommodate a rocket with a fin span of 16"

In this picture you can see the upper plywood with the hole now cut out. The lower plywood was laid out the same as the top one, only for this one I had to cut slots out for the bolts to go through. The rail will hold a rocket as small as 2" diameter, and as large a rocket as the 16" fin span will allow.

Here are the two pieces of plywood laying on top of each other. To get the idea of how this goes together, just imagine the plywood sections are 8' apart, with a wood frame-work on the outside.

Moving forward quite a bit here, the rail is basically done. The four corner supports are 1"x3"x8' pine boards screwed together to form an "L" at each corner, the 1"x3" strips were also used as cross supports. The rails the rocket will run against are 3/4" EMT conduit. As fate would have it, a 1/2" nut could be driven into the bottom of each piece of conduit. The conduit form fitted around the nut to secure it in place.

Here's the top end. The conduit was drilled and a 5/16" threaded rod screwed into the conduit, then welded in place. On top of the plywood is four wood blocks drilled out to 5/16" for the threaded rod to slide into.

I still have a few more screws to drive, and I'll prime and paint it. I'll also make a blast deflector of some sort and a retainer to hold the rocket off the ground a few inches.