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SpaceX starts stacking Starship’s first orbital-class Super Heavy booster

All but hidden behind Starship SN16, SpaceX appears to have begun stacking the first flightworthy Super Heavy booster. (NASASpaceflight - bocachicagal)

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By all appearances, SpaceX has begun the process of stacking what could become the first Super Heavy booster capable of supporting orbital Starship test flights.

Known as booster number 3 (BN3), numerous sections of the 70-meter-tall (230 ft) steel rocket have been spotted at SpaceX’s Boca Chica, Texas factory over the last six or so weeks – adding up to a substantial portion of what is now expected to be the first flightworthy Super Heavy. Earlier this year, SpaceX stacked Super Heavy BN1 to its full height but late design changes effectively rendered the prototype largely irrelevant and turned it into more of a manufacturing pathfinder and source of practice than anything else.

As a result, BN1 never even left the high bay it was built in before SpaceX workers cut the booster into scrap. As of May, while a handful of parts for booster number 2 have been spotted, signs indicate that BN2 will be turned into a small test tank to qualify Super Heavy’s complex and unproven thrust dome and engine section.

That leaves Super Heavy BN3. According to NASASpaceflight.com, SpaceX has nominally assigned booster BN3 to support Starship SN20 on its inaugural space launch attempt. Just last week, SpaceX filed an application with the FCC for permission to communicate with Starship and Super Heavy during that “orbital test flight” – paperwork that included a six-month launch window scheduled to open no earlier than June 20th.

If approved by the FCC and – far more importantly – the FAA, Starship’s first “orbital test flight” will circumnavigate three-quarters of the world in approximately 90 minutes, launching from Boca Chica and ending – if all goes well – with Starship SN20 gently splashing down near Kauai, Hawai’i. From the sparse documentation SpaceX included in the public application, it’s ambiguous if there will be an attempt to recover Super Heavy booster BN3 or if the test flight will actually be orbital, given that Starship SN20 wont complete a full orbit.

Technically speaking, although a Starship capable of safely launching from Texas to Hawai’i is almost unequivocally capable of reaching orbit, the safest possible “orbital” flight test for such a massive spacecraft would stop just shy of orbit. A guaranteed free-return reentry would make it almost impossible for Starship to reach orbit, fail to deorbit after its first ~90 minutes in space, and end up posing a risk to populated areas – like, say, the now-infamous boosters of China’s Long March 5B rocket. Regardless, it’s clear that the specifics of Starship’s first spaceflight attempt are still very much up in the air and liable to change over the next few weeks.

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Super Heavy BN3’s unique common dome section was completed and flipped earlier this month. (Jack Beyer – NASASpaceflight)
(NASASpaceflight – bocachicagal)
BN3’s engine section and thrust dome have also been more or less completed. (NASASpaceflight – bocachicagal)

What isn’t up in the air is the fact that SpaceX will need to all but fully assemble and test Super Heavy booster BN3 and Starship SN20 before any potential space shot. Along those lines, SpaceX still has a huge amount of work to do. Per Twitter user Brendan Lewis’ accounting, SpaceX has at least six BN3 sections – amounting to 22 rings and two of three tank domes – either completed or awaiting integration. The process of stacking BN3 began sometime in the last 7-10 days when SpaceX joined two four-ring sections – including the booster’s common dome, likely pictured above.

Looking more like a spaghetti monster than rocket part, this is likely the first 28-engine Super Heavy fuel manifold. (NASASpaceflight – bocachicagal)
A super (heavy) sized version of the methane transfer tube already used on Starship. (NASASpaceflight – bocachicagal)

SpaceX has mostly completed BN3’s engine section, including a thrust dome with plumbing cutouts for a full 28 Raptor engines. Most recently, what looks like a Super Heavy fuel manifold appeared in Boca Chica. That manifold will attach to the end of a supersized Super Heavy transfer tube – also spotted in work – used to route methane through the liquid oxygen tank to fuel its Raptor engines. Fueling 28 large, high-performance Raptors is no mean feat and requires a rat’s nest of plumbing to feed them more than 15 metric tons (~30,000 lb) of propellant every second at full throttle.

Put simply, a majority of Super Heavy booster BN3’s hardware appears to be ready or almost ready for integration. The eight rings now stacked represent approximately 20% of the rocket’s full height, leaving another 30 or so rings – 54m (~180 ft) – to go. Given how long BN1 assembly took SpaceX, the company has its work cut out for it to fully integrate BN3 by June 20th, and the first operational Super Heavy prototype will almost certainly need to complete several major tests before being cleared for flight. As such, an inaugural space launch attempt in June or July is wildly implausible, but it’s far from out of the question that Starship and Super Heavy could be ready for their first “orbital test flight” before summer turns to fall.

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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Tesla is already giving Robotaxi privileges hours after opening public app

This morning, Tesla launched the app in the Apple Store, giving iOS users the ability to download and join a waitlist in hopes of gaining access.

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tesla robotaxi app on phone
Credit: Tesla

Tesla is already giving Robotaxi privileges to those who downloaded the app and joined its waitlist just hours after it launched in the United States.

As the Robotaxi platform has been operating in Austin for several months, Tesla is now allowing the general public to download its app and call for a driverless ride in the city.

Tesla Robotaxi makes major expansion with official public app launch

The company previously sent invitations to select media outlets and Tesla influencers, seeking initial feedback on the performance of the Robotaxi platform.

There have been positive reviews, but, as with any Beta program, some mishaps have also occurred, although none have been significant.

As of the writing of this article, the City of Austin only lists one incident involving a Tesla Robotaxi, noting it as a “Safety Concern,” but not an accident or collision.

This morning, Tesla launched the app in the Apple Store, giving iOS users the ability to download and join a waitlist in hopes of gaining access.

Tesla is already granting Robotaxi access to several of those who have downloaded the app and gotten on the waitlist early:

With the launch of the public app, we were not too sure how soon Tesla would be able to initiate bringing more riders into the Robotaxi program. The immediate admittance for some riders just hours after the launch is a big positive and is surely a sign of strength for Tesla and its Robotaxi program.

What many will look for moving forward is the expansion of the geofence, which does not seem like a problem, as Tesla has already managed to do this on three occasions. The most recent expansion has expanded the service area to approximately 190 square miles.

People will also look for evidence of fleet expansion, a concern that has been a concern for many, especially since Tesla has not been completely transparent about it. They have revealed a recent service fleet growth of 50 percent, but there has been no specific number of vehicles mentioned.

Tesla reveals it has expanded its Robotaxi fleet in Austin

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Tesla explains why Robotaxis now have safety monitors in the driver’s seat

The update to Austin’s safety monitors became a point of interest among Tesla watchers on social media.

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Credit: Tesla

Tesla has provided an explanation about the presence of safety monitors in the driver’s seat of its autonomous Robotaxi units.

The autonomous ride-hailing service is currently being deployed in Austin and the Bay Area, with more cities across the United States expected to gain access to the service later this year.

Safety Monitors

When Tesla launched its initial Robotaxi program in Austin, the company made headlines for operating vehicles without a human in the driver’s seat. Even with this setup, however, Tesla still had safety monitors in the passenger seat of the Robotaxis. The safety monitors, which do not interact with passengers, have been observed to report issues and other behaviors from the autonomous vehicles in real time. 

Safety monitors on the driver’s seat were also employed in the service’s Bay Area rollout, though numerous members of the EV community speculated that this was likely done to meet regulations in California. However, with the expansion of the Austin geofence, riders in Tesla’s Robotaxis observed that the safety monitors in the city have been moved to the driver’s seat as well.

Tesla’s explanation

The update to Austin’s safety monitors became a point of interest among Tesla watchers on social media. Longtime FSD tester Whole Mars Catalog, for one, speculated that the move might be due to Texas’ new regulations for autonomous vehicles, which took effect recently. Interestingly enough, the official Tesla Robotaxi account on X responded to the FSD tester, providing an explanation behind the safety monitor’s move to the driver’s seat. 

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“Safety monitors are only in the driver’s seat for trips that involve highway driving, as a self-imposed cautious first step toward expanding to highways,” the Tesla Robotaxi account noted.

Tesla has been extremely cautious with its autonomous driving program, particularly with the rollout of its Robotaxi service, which use Unsupervised FSD. This is quite understandable considering the negative media slant that Tesla is consistently subjected to, which could very well result in minute incidents or mistakes by Robotaxis being blown out of proportion.

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Elon Musk

The Boring Company begins hiring for Nashville’s Music City Loop

Tennessee Gov. Bill Lee expressed strong support for the project.

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Credit: The Boring Company/X

Elon Musk’s The Boring Company has started recruitment efforts for the Music City Loop, an underground tunnel system designed to link downtown Nashville with Nashville International Airport. 

Tennessee Gov. Bill Lee expressed strong support for the project, describing it as a cost-free alternative to traditional mass transit systems that could ease traffic congestion in the city. Initial digging began in mid-August, with visible progress reported by September 1, as noted in a WKRN report.

Job creation and project scope

The Boring Company is currently seeking engineers, electricians, mechanics, and operations coordinators as part of its hiring drive for the Music City Loop in Nashville. Gov. Lee emphasized that unlike large-scale transit projects that typically cost billions, the tunnel system will not burden taxpayers.

“We’ve been trying to find ways, Metro Nashville has in particular, to develop transit in the city for a long time. It costs billions and billions of dollars to build out transit systems. We now have an opportunity to have a transit system that costs the taxpayers nothing,” Lee said, calling the effort the fast lane to the city’s future.

The Music City Loop aims to provide a quick and efficient link between the city center and the airport, similar to The Boring Company’s other tunnel projects like the Las Vegas Convention Center Loop. Officials have praised the company for cooperating with state permitting and regulatory requirements, suggesting that the Nashville Loop project is advancing in line with established processes.

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Community reactions and concerns

While officials are optimistic, community response has been mixed. Some residents have raised concerns about the speed of approval and a lack of public discussion before construction began.

Nashville resident Taylor John cited environmental impacts and worries that the tunnel could primarily serve tourists rather than local commuters. “I have a lot of concerns, first of all, by how fast this decision was made, I don’t think there was a lot of discussion from the members of the community before this decision was made. It’s going to impact us,” the resident stated.

Others, however, see the project as an innovative leap forward. “There’s a whole untapped potential underneath our feet,” resident Nathaniel Lehrer stated. “Anything that can save time when picking up family or friends or you need to catch a flight, it’d be an awesome option to have.”

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