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SpaceX’s Mr. Steven returns with Falcon fairing half in net after drop test practice
Captured in a series of photos taken by Teslarati photographers Pauline Acalin and Tom Cross over several days, SpaceX Falcon fairing recovery vessel Mr. Steven and recovery technicians and engineers have been preparing and practicing for a campaign of controlled fairing drop tests.
By using a helicopter to lift and drop a fairing into Mr. Steven’s net, SpaceX will be able to gather an unprecedented amount of data and control far more variables that might impact the success of recoveries. If the fairing is not destroyed in the process, this test series could be as long-lived as SpaceX’s Grasshopper program, used to work the largest up-front kinks out of Falcon 9 booster recovery.
Mr Steven looks ready. Should be leaving port at some point today ahead of SAOCOM-1A launch scheduled for Sunday, Oct 7, 7:21pm PT #mrsteven #SpaceX pic.twitter.com/Hk7HLmMDra
— Pauline Acalin (@w00ki33) October 6, 2018
Although SpaceX technicians managed to reassemble and install Mr. Steven’s net and arm fairing recovery mechanisms in just a handful of days, finishing less than 48 hours before the West Coast launch of SAOCOM 1A, the ship remained in port for the mission, passing up its fifth opportunity to attempt recovery of one of Falcon 9’s two fairings halves. Why exactly Mr. Steven never left port is unclear and unconfirmed, although SpaceX did mention that recovery would not be attempted this time around during its official launch webcast.
The most likely explanation is mundane – sea states with average swells as large as 4m (13ft) were forecasted (and later recorded) at and around the optimal fairing recovery zone. As a Fast Supply Vessel (FSV) explicitly designed to rapidly and reliably resupply oil rigs and other maritime work areas almost regardless of weather conditions, 4m waves would normally be a tiny pittance for ships as large and heavy as Mr. Steven and would be a nonsensical reason to halt deep-sea operations.
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- Thanks to their relatively high angle of attack, Mr. Steven’s newest arms should not seriously impact his stability, but there is a chance that they limit his operational envelope in high sea-states. (Chuck Bennett)
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- Mr. Steven seen listing roughly 5 degrees to port during arm installation, July 10th. (Pauline Acalin)
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- A few-degree list seen during fairing recovery practice, August 13th. (Pauline Acalin)
On the other hand, Mr. Steven is without a doubt the most unusual FSV in existence thanks to his massive arms and net, stretching at least 60m by 60m. Based on photos of the arm installation process, significant lists of 5+ degrees are not uncommon when arms are unbalanced during normal staggered (one-at-a-time) installations, and SpaceX quite clearly installs the first two arms on opposite sides and orientations in order to minimize installation-related listing. This indicates that his newest arms have significant mass and thus leverage over the boat’s roll characteristics, perhaps explaining why Mr. Steven has performed anywhere from 5-10 high-speed trials at sea both with and without arms installed.
Most recently, however, Mr. Steven spent a solid six weeks armless at Berth 240 while some sort of maintenance, analysis, or upgrade was undertaken with those four arms and their eight shock-absorbing booms. It’s hard to know for sure, but there are no obvious visual changes between the arms installed in July and August and those now present on his deck, and the net also looks almost identical.
Fairing drop tests?
What’s less familiar these days is an oddly arranged Falcon 9 payload fairing half that has been floating around SpaceX’s Port of Los Angeles berths for the last two or so weeks. Up until October 4th, the purpose of that single half was almost entirely unclear. On October 4th, Teslarati’s entire space team (Tom, Pauline, and I) coincidentally arrived at the same time as 5-10 SpaceX technicians were working on the fairing, attaching a series of guylines and harnesses and inspecting a number of actuating mechanisms on the half.
Just minutes after we arrived, a worker called out a short countdown and a wholly unexpected crashing noise sounded, followed immediately by several loud clangs as the harness connection mechanisms swung back and connected with metallic parts of the fairing. After the adrenaline wore off, the initial crashing noise was almost certainly the sound of the same mechanical jettison mechanism used to separate fairing halves ~3 minutes after the rocket lifts off.
Once photos of the event could be examined more carefully, that was exactly what we found – the six harness connections were attached to the fairing by way of the same mechanical interface that allows two halves to safely attach to each other. What we had witnessed was a harness separation test, using pressurized gas stored in COPVs (the gold striped cylinders) to rapidly actuate a latch, allowing the metal harness connectors to fall away. This is further evidenced by the presence of neon orange zip-ties connecting the ends of those harnesses to any sturdy fairing structure near the connection port, an easy and (presumably) affordable way to prevent those heavy connectors from swinging down and damaging sensitive piping and components.
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- An overview of the weird fairing test article just before the harnesses were jettisoned. (Pauline Acalin)
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- Note the taut, yellow ropes connected to the fairing at its original serparation connector ports. (Pauline Acalin)
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- Zip-ties prevented the harness connectors from smashing (too hard) into the fairing’s innards. (Pauline Acalin)
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- A Falcon 9 fairing during encapsulation, when a launch payload is sealed inside the fairing’s two halves. This small satellite is NASA’s TESS, launched in April 2018. (NASA)
According to someone familiar with these activities, the purpose of that testing is to prepare for true fairing drop tests from a helicopter. The jettisonable harness would be a necessity for easy drop testing, allowing the helicopter to carry a basic cargo hook and line while technicians inside communicate with the fairing to engage its built-in separation mechanism, all while ensuring that it immediately begins a stable glide or free-fall after dropping.
Observed on October 4th, it was at least moderately disappointing to see Mr. Steven remain in port during the spectacular Falcon 9 launch of SAOCOM 1A, October 7th. Reasons aside, roughly 12 hours after launch, Mr. Steven left on a 10+ hour cruise ~100 miles off the coast, where he repeatedly met up with tugboat Tommy and circled Santa Catalina Island once before heading back to port. Just 24 hours before launch (Oct. 6), the test fairing seen above was placed in Mr. Steven’s net for communications and harness testing – 24 hours after launch, Mr. Steven returned to Port of San Pedro after his 10-hour cruise with the same fairing half resting in his net.
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- Mr. Steven returned to Port of San Pedro around 7pm on October 8th after a day spent at sea, apparently with a Falcon fairing half in tow. This is the second known time that a fairing has been in Mr. Steven’s net. (Pauline Acalin)
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- An overlay of the paths of travel of a test-related helicopter and Mr. Steven, both on Oct. 8. The yellow plane is the heli at the beginning of a hover, while the gap between blue triangles in the lower left is where Mr. Steven was during that hover. (MarineTraffic + Flightradar24)
How and why it got there is unknown, as is the purpose of half a day spent boating around with the half in his net. However, a helicopter known to be involved in fairing drop tests was seen hovering and flying around Mr. Steven at the same time. Perhaps the two were practicing for real drop attempts, or perhaps the helicopter actually dropped a Falcon fairing (from > 2000 feet) and Mr. Steven successful caught it.
What is clear is that SpaceX is just getting started with efforts to perfect fairing recovery and eventually make the practice as (relatively) routine as Falcon 9 booster recovery and reuse is today. The latter was hardwon and the former will clearly be no easier.
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News
SpaceX set to launch astronauts and a classified Falcon Heavy mission on the same day
SpaceX plans three launches Thursday, including Crew-13 astronauts and Falcon Heavy’s first classified NRO mission.
SpaceX is lining up one of the busiest single days in its history, and the company offered a preview on Wednesday morning with a simple post on X: “Sunrise at pad 40.” The video and photos show Falcon 9 standing at Space Launch Complex 40 at Cape Canaveral, roughly a day before it is scheduled to carry four astronauts to the International Space Station.
That launch is only the first of three SpaceX missions planned for Thursday, October 1, across both coasts.
Sunrise at pad 40 pic.twitter.com/J7Qme4VvIX
— SpaceX (@SpaceX) September 30, 2026
Crew-13 is targeting liftoff at 11:10 a.m. ET, with a backup opportunity Friday at 10:47 a.m. ET. NASA astronaut Jessica Watkins will command the mission, with NASA’s Luke Delaney as pilot and Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov serving as mission specialists. According to NASA, Dragon is set to dock with the forward port of the station’s Harmony module around 8 p.m. ET, less than nine hours after launch. Watkins is the only member of the crew who has flown before, and Kutryk will become the first Canadian to reach orbit through NASA’s Commercial Crew Program.
The Falcon 9 booster is flying for the third time after supporting Crew-12 and a Starlink mission, and it will attempt a landing at Landing Zone 40 beside the pad. That site made its debut in February when the Crew-12 booster touched down there, as Teslarati reported at the time. Crew-13 will relieve the Crew-12 astronauts, who have been aboard the station since the middle of February.
On the West Coast, another Falcon 9 is scheduled to lift off from Vandenberg Space Force Base in a window running from 2:18 to 3:16 p.m. ET, a flight NASASpaceflight lists as a Transporter rideshare mission.
The day is set to close at 11:53 p.m. ET, when Falcon Heavy launches from Launch Complex 39A with NROL-97, the first National Reconnaissance Office payload ever to fly on the rocket. SpaceX rolled the vehicle out to the pad Tuesday night. Its two side boosters, which previously flew GOES-U, ViaSat-3 F3 and NASA’s Roman Space Telescope, will return to Landing Zones 1 and 2, while a new center core will be expended in the Atlantic. The Roman launch took place on August 30, so NROL-97 will come barely a month later as Falcon Heavy’s third flight of 2026 and 14th overall.
NASA taps SpaceX to launch the telescope that could unlock new worlds
If all three Florida boosters land as planned, it would be the first time the Space Coast has seen landings at LZ-40, LZ-1 and LZ-2 on the same day, according to the Orlando Sentinel, which has warned residents in Brevard, Orange and Volusia counties that more than one sonic boom is possible.
The schedule arrives just three days after Starship reached orbit for the first time on Flight 14 from Starbase, Texas, deploying 26 Starlink V3 satellites. If Thursday’s missions stay on time, SpaceX will have flown Starship, Falcon 9 and Falcon Heavy from four different pads in about four days.
Crew-13 is also the start of a longer run for Dragon. NASA recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification, keeping Dragon as the agency’s only operational ride to the station while Boeing’s Starliner remains grounded.
Although the two vehicles are built for completely different use cases, Tesla utilized engineering expertise while developing both the Cybercab and Semi to build a thermal architecture that would fit both vehicles. Of course, with some slight revisions.
The development was noted by Lars Moravy and Dan Priestley last week at Tesla’s Semi Handover event in Sparks, Nevada, where the company showed off its dedicated production facility for the Class 8 truck.
🚨 Tesla designed the integrated thermal systems for Cybercab and Semi at the same time as the vehicles were both in development
Tesla wanted to build one thermal system that worked with both vehicles, apart from small modifications.
Semi and Cybercab share parts 🤯 pic.twitter.com/KmzSsUbrcg
— TESLARATI (@Teslarati) September 25, 2026
Tesla’s decision to develop one thermal architecture for both the Cybercab and Semi is one of the more revealing engineering choices in the company’s 2026 lineup:
“We designed it at the same time we designed the Cybercab and we said okay we’re going to take our most efficient vehicle and our biggest vehicle and we’re going to take one thermal system and make it work for both.”
Core parts, meaning the compressor, pumps, and heat exchangers, are shared, with only modest changes to cooling-loop sizing and a larger radiator on the truck. The result, they said, is a compressor and thermal stack already proven across millions of miles, delivering “reliability from day one.”
Priestley also highlighted a practical payoff of the indirect design:
“There’s no AC lines, there’s no refrigerant lines…It comes from the factory fully charged, sealed with refrigerant, and it just exchanges coolant. It doesn’t actually run refrigerant up to the front of the vehicle.”
This eliminates potentially leak-prone plumbing that would otherwise require hands-on service, reducing overall uptime and potentially cutting into business margins. The megamanifold runs cabin HVAC and every powertrain heating and cooling loop at once, recapturing waste heat from motors and the battery instead of dumping it the way a diesel engine does.
The approach is just the latest chapter in a continuing story of stretching thermal solutions across wildly different vehicles. Model Y’s Octovalve evolved into the Super Manifold used on Cybertruck, and later Model S/X refreshes. Cybercab then introduced Supermanifold V3, which Tesla says is 80 percent automated to build and 38 percent more efficient than typical automotive thermal systems.
This thermal system is also shared with Cybercab – one thermal system for both our most efficient vehicle & our biggest vehicle
— Tesla Semi (@tesla_semi) September 25, 2026
Tesla has done the same with the 4680 cells, both being utilized in the Cybertruck and Semi, and with heat-pump compressors that Priestley noted were already common across the passenger-car fleet.
Concurrent development of crucial vehicle elements buys scale and reliability that a truck-only thermal system could not match. High-volume passenger car parts are cheaper and more accessible, which can give fleets a sealed, low-maintenance loop of operation from their first day of operation.
For owners and operators, that translates into less energy spent on cabin heat in the colder months, fewer refrigerant-related repairs, and a thermal architecture already stress-tested at passenger-car volumes before the first high-volume Semi left the lines in Nevada.
Tesla CEO Elon Musk certainly tipped off some details of the Tesla Roadster event with a broadening of information regarding the company’s decision to delay the unveiling for two weeks.
For years, people have speculated about what the Roadster will be capable of. While there have been plenty of things said about what it *could* do, we have not seen or been told by Tesla what it will actually be capable of.
However, over the past few days, Tesla’s weather updates have truly pushed the speculation into Plaid Mode, basically all but confirming the car will have some sort of aerial capability — whether that would be hovering or fully flying remains to be seen — but it definitely seems that it will be able to leave the ground intentionally.
“Because this event can only be held outdoors…”
Tesla posted on Monday that it would delay the Roadster event until October 15, and it indicated that it had to do this because the event “can only be held outdoors.”
With the potential SpaceX collaboration to develop cold-gas thrusters that will help the vehicle go airborne, doing this indoors is probably not a safe, or even plausible, possibility.
Roadster event update
We’ve been tracking the weather closely with local meteorologists, but given the severe conditions predicted & because this event can only be held outdoors, we’ve made the difficult decision to reschedule.
New date is October 15. Additional details to…
— Tesla (@Tesla) September 28, 2026
FAA Airspace Restriction
The FAA gave Tesla a Temporary Flight Restriction (TFR) for 10,000 feet above ground level, much higher than the typical 2,000-foot restrictions that are usually placed at SpaceX’s McGregor, Texas site.
Tesla Roadster event requires restricted airspace, and the FAA obliges
Some have said that this massive increase is due to Tesla’s need to restrict unauthorized drone use for spying on the event.
Elon Admits High Winds
“Due to high winds, the new Roadster demo is postponed by 2 weeks,” Musk said in a post on X yesterday.
Due to high winds, the new Roadster demo is postponed by 2 weeks https://t.co/dV3ojDh1iT
— Elon Musk (@elonmusk) September 30, 2026
A reply reading, “What’s strong wind got to do with a car demo with four grounded wheels?” was directly below Musk’s post, satirically and sarcastically probing for more details.
All signs are pointing toward an aerial demonstration for the Roadster.
SpaceX set to launch astronauts and a classified Falcon Heavy mission on the same day
Tesla Cybercab and Semi have more in common than you might think
