Inspired by SpaceX's self-landing rockets, I decided to make my own version. This rocket has two body tubes - an upper one (with leg holders and support struts) and a lower one (with fins and landing legs). After the rocket launches, the motor's ejection charge will seperate the top and bottom parts, lifting the leg holders off the legs and allowing them to extend. Then, both parts will come down separately, each with their own parachutes, and the bottom part will land on its legs. Here is a step-by-step breakdown of how I am making this rocket:
The 3 landing legs: They needed to be strong but lightweight, so I am using wood with many holes in it. The legs are also three-dimensional to provide more support and alleviate stress. There are a few other features (like notches and holes), whose purpose will be discussed later.
2. The three landing leg holders: For most of the rocket's flight, the landing legs should be held next to the rocket for aerodynamic and stability purposes; only at the very end should they deploy for the rocket to land. The leg holders are made out of wood to be strong, but have holes cut into them to be lightweight. They are also made to be aerodynamic because they will be sticking out the side of the rocket.
3. The support struts: Since there will be many holes cut into the rocket to fit all the wooden pieces, the body will become weaker. So, I made lightweight and aerodynamic wooden support struts:
4. I attached the support struts and leg holders to the upper tube of the rocket. I also attached a red tube coupler, which will hold the two parts of the rocket together until they are separated.
5. Landing leg feet: The landing leg feet will spring out when the stages separate. Here is a picture and video of this mechanism in action:
6. I attached the upper stage parachute to a hook in the red coupler, as well as the nose cone to the top of the rocket:
7. The fins: I first attached the fins and centering rings to the motor tube, which will all be put into the body tube later. I then attached a shock cord for the parachute to two metal hooks. The fins have holes in them because that is what the legs will pivot around when they are deployed.
8. Attaching the fin assembly to the rocket. Glue was put on the inside because if it was on the outside, that would increase drag on the rocket.
The launch lugs (tubes which will guide the rocket along the launch rail) were attached, and slots were cut into the tube for the fins.
The fin assembly was put into the slots in the tube. Tape was put on the outside so that glue would not leak out.
The back ring centering ring was taken off, allowing me to put internal glue fillets between the fins and tube.
The back centering ring was glued on after I finished putting in glue. You can see the tape which is preventing glue from leaking out.
The fins are now attached, and the glue is drying. The parachute (blue on the right) was attached to the shock cord.
9. I attached the legs to the fins. The way they work is that there is a rubber band attached from a leg to a fin. When the upper stage is removed, that rubber band brings the leg into place. Once the leg is in place, to make sure it says there, there is a little wooden piece with a small rubber band. That piece slides into a nook in the leg and keeps the leg in place.
Here is a video of one of the legs unfolding and locking into place:
Here is the completed rocket: