The Power Plug

 The Thrifty Rocketeer blog continues...


One of the unsung heroes of the model rocket launch, is the power leads.

Now, after the Estes Launch controller, most launch systems rely upon long 25 ft or 50 ft orange extension cords to run out to the launch pad.  Most are 3 element grounded cords and are easily visible when laying on the ground.

Most launch controllers accept the male end into the female end panel mounted socket for each launch circuit.

But it's the other end, where the cord meets the ignitor and the actual exhaust blast of the rocket that I'm talking about.

The lead running from the power cord to the igniter is basically a molded male end of a short power cord.  It typically ends in two  wires with allegator clips crimped or soldered onto the wire, so that the rocketeer may pinch clip to the exposed wires of the starter/igniter.

Now, you might think that this part would only have to be constructed once, and work for years and years. But remember that the allegator clips are exposed to hot rocket exhaust at temperatures that would cook you or I if were held our hand there.  In fact, most all launch pads have a metal blast plate to deflect those hot gases from melting the plastic parts.  As a result, the blast plate gets rather scarred, scorched, and rusty very quickly.

Why wouldn't the allegator clips?

Most clubs have to refurbish and replace their clips at least once a season, and so that typically means replacing that lead from the male power plug or else cutting off the non-functioning allegator clips and replacing them.  Typically, this means cutting and stripping the wires before crimping the clips on.

Now, I am told there is a very short video that demonstrates the proper way to crimp on such a test lead clip.  You would think that it doesn't matter, but remember the high temps that the clips must endure.  That could melt solder easily.  And the correct method of crimping involves folding the center wire back over the insulation so that the crimp not only pinches the insulation but also hold the wire in constant contact.  This acts as a strain relief and keeps the clip from pulling off.

If you have an alternative method of attaching these workhorses of the rocketry community, please forward it to me.

This has been the Thrifty Rocketeer, reminding you to save your cord from your "Major Award" this Christmas season, and repurpose it as a launch lead.


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