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SpaceX rolls Super Heavy booster to orbital launch mount

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5 years ago

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For the third time in four months, SpaceX has rolled the first potentially flightworthy Super Heavy booster towards Starbase’s orbital launch mount.

Combined with a large crane – fitted with a jig solely used to lift boosters – moving to a spot just beside the booster, it’s clear that SpaceX is preparing to reinstall Super Heavy Booster 4 (B4) on the orbital launch mount. In the context of its unusual history, though, what happens next to the first more or less finished prototype of the largest rocket booster ever built is less clear.

After a shockingly quick assembly over the course of six summer weeks, Super Heavy Booster 4 rolled out of Starbase’s ‘high bay’ facility and headed to the nearby orbital launch complex, where it was installed on a custom ‘mount’ designed to support booster testing and orbital launches. It’s now clear that during that early August photo opportunity and fit test, Booster 4 was nowhere close to finished. Nor, apparently, was it anywhere close to complete one month later when it returned to the orbital pad for the second time after another few weeks of work back at the high bay.

August 6th. (SpaceX)
September 7th. (Starship Gazer)

Three months (almost 14 weeks or 100 days) after the Super Heavy prototype’s second trip to the pad, SpaceX has yet to attempt to put the booster through a single proof test. There also appears to be a significant amount of work left to finish installing external ‘aerocovers’ and a heat shield meant to enclose all 29 of its Raptor engines. In the three-year history of Starbase, there isn’t a single prototype of the roughly two-dozen SpaceX has built, tested, and even flown that’s spent even half as long as Super Heavy B4 between apparent structural completion and its first test. Perhaps the fact that Booster 4 is a first-of-its-kind pathfinder explains SpaceX’s uncharacteristic sluggishness or reluctance to actually test the rocket.

In every other instance, SpaceX’s approach to Starship development has been to move incredibly quickly, build a large number of prototypes, and rapidly test those prototypes – often resulting in catastrophic failures. Data is gathered from those failures (SN1, SN3, SN4, SN8, SN9, SN10, SN11, and half a dozen smaller test tanks serve as examples), changes are made, and then the new and improved prototypes that follow repeat the process until SpaceX arrives at a successful design.

Super Heavy B4’s circuitous path has been almost nothing like those of its predecessors. That could also be partly explained by the unavailability of a stand or facilities capable of truly proof testing a Super Heavy, which necessitates a supply of around 3200 tons (7M lb) of liquid nitrogen (LN2; for a cryogenic proof test with full tanks), another 3200 tons of a combination of liquid methane (LCH4) and oxygen (LOx), and the ability to ignite – and survive – as many as 29 to 33 Raptor engines. The suborbital stands SpaceX has used to proof Starships and even Super Heavy Booster 3 don’t even have half the storage capacity required to fully test a booster and the mounts and their surroundings would likely be catastrophically damaged or destroyed by the thrust and blast created by dozens of Raptors.

Still, SpaceX could have theoretically put Booster 4 through a partial cryoproof and maybe fired up as many as nine Raptors at once – not a replacement for full proof testing but still plenty to ensure Super Heavy’s structural integrity and gather invaluable data on clustered Raptor performance. Instead, of course, Super Heavy B4 has sat at Starbase’s former landing zone for more than three months while teams removed engines, reinstalled engines, half-installed a full Raptor heat shield; and installed two of six or seven ‘aerocovers’ needed to protect heat exchangers, racks of pressure vessels, and hydraulic systems installed on the booster’s aft.

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Booster 4’s half-finished aft as of December 11th. (NASASpaceflight – bocachicagal)
B4 rolls towards the launch mount on December 12th. (NASASpaceflight – bocachicagal)

This is all to say that from the outside looking in, Booster 4’s path towards testing and flight has been almost entirely different from that of any other Starship prototype. While still quick in comparison with other launch vehicle development programs, relative to other Starship and Super Heavy prototypes, the rate of B4 progress has been far slower – strongly implying that something is seriously wrong with the booster, that SpaceX no longer feels that partial testing is worth the effort, that finishing Booster 4 just hasn’t been a priority for several months, or some combination of the above.

What that ultimately means is that it’s almost impossible to predict what Super Heavy B4’s future holds beyond the clear evidence that SpaceX will soon reinstall to reinstall it on an orbital launch mount that’s much closer to completion than it was the last time B4 was installed. At this point, it’s just as likely that the booster’s third launch mount installation will just be another mechanical fit test, though the hope is that it will kick off full-scale pneumatic and cryogenic proof testing. It could even culminate in the static fire of some or all of its 29 Raptor engines, which have been installed for several months.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Elon Musk

Elon Musk and Trump are closer than ever, and Tesla could be the big winner

Elon Musk sat beside Trump as AI leaders signed a voluntary White House safety accord.

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2 hours ago

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September 29, 2026

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Elon Musk had the seat right next to President Donald Trump on Tuesday as the White House hosted the leaders of America’s biggest artificial intelligence companies for a lunch that ended with a voluntary industry accord on AI safety.

A seating chart Trump posted on Truth Social placed Musk at the president’s left in the East Room, with Nvidia CEO Jensen Huang on his right, according to an Associated Press reporter. Anthropic CEO Dario Amodei, OpenAI President Greg Brockman, Meta’s Mark Zuckerberg, Google’s Sundar Pichai, Microsoft’s Satya Nadella and Amazon founder Jeff Bezos also attended, along with Vice President JD Vance and House Speaker Mike Johnson.

After the lunch, Trump told reporters outside the West Wing that the executives had signed “The White House Accord on Superintelligence: A Joint Commitment on Frontier SI Responsibilities.” Johnson described it as a voluntary statement of principles built on “robust internal controls and layers of internal and external review,” while Zuckerberg said company boards would independently review reports from outside auditors. Trump called the document “morally binding,” said he would name a new AI czar within days, and signed an executive order formally renaming artificial intelligence “super intelligence,” CNBC reported.

Musk was not in the room for Tesla alone. Since SpaceX absorbed xAI, he runs the company behind Grok and one of the largest AI training operations anywhere. On September 25, he said another 220,000 Nvidia GB300 chips would come online at Colossus 2 within a week, with more expected in November and December.

SpaceX confirms third massive compute deal at Colossus data center

 

Musk also used the trip to restate his energy ambitions. “SpaceX is aiming together with Tesla to do 200 gigawatts of solar production per year,” he said at an event in Washington. It is the same combined target he laid out that feeds directly into Terafab, the Tesla and SpaceX chip venture that will need enormous amounts of power.

The showing between Musk and Trump has come a long way, since the two had the very public split in mid 2025 after Musk opposed the “Big Beautiful Bill” and left DOGE. They reconciled at Charlie Kirk’s memorial that September, and Trump later called their relationship “good”. Since then, Musk has joined Trump’s China delegation in May and attended last week’s White House state dinner for Chinese President Xi Jinping.

For Tesla, that access to government official could pay dividends. As Teslarati noted in January, federal autonomy rules, NHTSA oversight and a single national standard for driverless vehicles all run through an administration Musk can more easily reach directly as Tesla works to scale Robotaxi and Cybercab beyond Texas.

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Elon Musk

Tesla Roadster’s new patent preps white-knuckle speeds, keeping it grounded

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15 hours ago

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September 29, 2026

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Credit: @BLKMDL3/Twitter

Ahead of its highly anticipated unveiling, Tesla’s upcoming Roadster received a new patent that aims to keep it grounded while enabling white-knuckle speeds.

The patent, which was granted on September 29, is titled “Electric Car Fan,” bluntly stating its design but not its purpose, which is further detailed in the text of the application. Interestingly, it comes two weeks before the Roadster event, which was delayed due to unfavorable weather on Thursday, which could cause issues, as Tesla revealed the event must be held outdoors.

The purpose is to solve a problem that is relatively unique to high-performance electric cars. Instant motor torque is useless if the tires cannot plant that force, and conventional wings and underbody tunnels generate downforce only when air is already rushing past the car. At launch, in slow corners, and under hard braking from modest speed, passive aerodynamic additions contribute essentially very little to downforce.

Tesla’s filing says that its fans can produce the downforce needed, independent of vehicle velocity, then ease off so the same hardware does not pile on drag at highway speeds, an issue that can come from excessive body modifications.

The hardware outlined in the patent is a ducted-fan package that is placed into the rear of the vehicle. An underbody inlet between the rear wheels feeds a duct that rises to a wide outlet in the diffuser. In that outlet are four axial fans, which are divided by vertical strakes. They will pull air from under the floor and press the chassis onto the pavement.

The language in the patent claims it can cut drag rather than add to it while simultaneously increasing downforce.

Tesla Roadster event requires restricted airspace, and the FAA obliges

The fans run from the high-voltage battery and a vehicle control system, so output can be modulated rather than left on as a fixed penalty.

There are additional strengths that can come from this design, like extra tire load at low speed, which can contribute to even more face-melting acceleration rates, decrease stopping distance, and sharper turn-in before a wing has air to work with. Adjustable fan speed lets the car add grip only when needed, so it can be catered to the force of a turn or acceleration.

These designs were previously used, and banned, in some competitive settings. The Brabham BT46B was banned in F1 competition for using a similar fan design and being labeled as too effective.

Tesla still lists the Roadster as having a sub-two-second 0-60 MPH time and a 250-plus-MPH top speed, and there are expectations for a SpaceX cold-gas thruster package that could not only increase acceleration but potentially cause the vehicle to hover.

It is important to note that a patent is not a production part, and packaging four fans in a rear diffuser, managing noise, and potential debris are all things Tesla must consider. With that being said, the patent being granted shows Tesla is designing the Roadster to go fast, but it is also attempting to use unique strategies to combat any issues it might have at those speeds.

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Investor's Corner

Tesla showrooms picked clean ahead of Q3 end as demand looks strong

Published

17 hours ago

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September 29, 2026

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Credit: @thaichiminh1907/X

Tesla (NASDAQ: TSLA) showrooms have been picked clean ahead of the end of the third quarter of the year, as demand looks to be strong and delivery estimates for new vehicles are pushed into late 2026 and early 2027.

Tesla appears to have sold out of many of its Model 3 and Model Y trim levels in the United States, as only the Model Y RWD and Model Y All-Wheel-Drive are available for delivery before the end of the year.

Additionally, many showrooms are either completely empty or void of all but just one demo unit within the buildings themselves in an effort to bolster what could be one of Tesla’s best quarters in vehicle deliveries in recent memory.

Additionally, when I spoke to the guys at Tesla Mechanicsburg two weeks ago, when I returned the Model Y L, their third hauler of the week had just arrived, and every vehicle on it, along with every vehicle in their delivery lot, was accounted for and had a name attached to it for delivery.

Tesla saw a 25 percent increase in deliveries in Q2 compared to the same quarter the year before. The vast majority of the 480,126 units it delivered, 467,762 vehicles to be exact, were the Model 3 and Model Y.

In Q3 2025, Tesla delivered 497,099 vehicles, once again a figure that was dominated by the company’s two mass-market vehicles. Analysts have unusually wide predictions for this quarter, likely because so many firms missed the Q2 delivery figure by such a substantial margin; Wall Street predicted 408,000 cars, while Tesla delivered 480,000.

Goldman Sachs has Tesla slotted for 435,000 deliveries in Q3, while JPMorgan said it anticipates 482,000. The median guess is about 449,000 deliveries for Q3.

Interested in ordering a Tesla? Use my referral code for three free months of Full Self-Driving (Supervised) here.

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