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SpaceX preparing Super Heavy, Starbase for booster’s next steps

Booster 4 awaits its moment in the spotlight. (NASASpaceflight - bocachicagal)

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Amid a flurry of deliveries and work on several new Starship boosters, SpaceX is preparing the first truly finished Super Heavy for its next steps.

Partially completed by early September, Super Heavy Booster 4 (B4) supported SpaceX’s iconic ‘full stack’ fit test back on August 6th before returning to the build site but has mostly just floated around Starbase’s launch and test facilities in the seven weeks since its second trip to the pad. On September 10th, CEO Elon Musk himself suggested that SpaceX had plans to static fire the booster as early as mid-September – more than six weeks ago. Obviously, nothing even approximating Super Heavy testing transpired. Instead, at least relative to rapid-fire Starbase operations in the two years prior, SpaceX has almost absentmindedly worked on the booster, mostly completing partially-finished wire runs that run its full 69m (~225 ft) length.

In the last few weeks, though, the type of work being done on Super Heavy B4 has changed.

Completed on August 6th, Super Heavy B4’s first ‘test’ was more of a photo-op. (SpaceX)
Booster 4 rolled to Starbase’s orbital launch pad for the second time on September 7th. (Starship Gazer)
B4 was removed from the launch mount a second time on September 26th. (NASASpaceflight – bocachicagal)

On September 26th, to give the Starbase construction crew more room to install giant arms on the orbital pad’s ‘launch tower,’ SpaceX removed Super Heavy B4 from the launch mount for the second time, temporarily relocating it to an unused patch of the pad’s old landing zone. Booster 4 hasn’t been moved since. However, while probably a bit slower than SpaceX would have liked, large-scale work on the Starship launch tower was effectively completed last week with the installation of two giant rocket-catching ‘Mechazilla’ arms.

A great deal of work has also been done on Starbase’s orbital tank farm over the last two months, including the installation of the last few storage tanks, the ‘sleeving’ of those tanks, a great deal of plumbing, and the start of real propellant deliveries. Save for a few days spent testing Starship S20 in late September and mid-October, the pad construction crews that have to evacuate the pad for 6-12 hours for every test have had three full months to work without interruption. Perhaps the most optimistic explanation for the unusually long gap between Booster 4 and Ship 20 rollout and testing is that SpaceX consciously chose to put off vehicle tests to avoid disrupting orbital launch site construction and retasked nearly all Starbase workers for that construction.

Regardless, with the launch tower and orbital tank farm now more or less structurally complete and work already underway to prepare the tank farm to support its first booster tests, most of the work that may have been drawing focus and resources away from ship and booster preparations appears to be wrapping up. That may be why, for the third time, SpaceX technicians began removing a number of Raptor engines from Super Heavy B4 around the start of October.

Aside from removing around a third to half of Super Heavy’s 29 Raptors, SpaceX also began slowly but surely installing parts of a steel heatshield designed to protect those engines during ground testing, ascent, and reentry. Newer Raptors have also been trickling from Starbase’s build site to the launch pad for installation on the booster and more engines will likely be (re)installed as heatshield installation progresses.

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The start of Super Heavy’s Raptor shield. (NASASpaceflight – bocachicagal)

Perhaps the most unusual part of recent Super Heavy B4 work is the apparent application of some kind of foam around several racks of pressure vessels (COPVs), hydraulic manifolds, and umbilical connections installed around the booster’s base. Those racks will eventually be enclosed inside steel ‘aerocovers’ already staged beside Super Heavy. A number of Twitter users believe that the foam being selectively applied is for acoustic deadening – meant to protect sensitive electronics, valves, and computers from the brutal environment Super Heavy itself will produce at liftoff and during ground testing.

Ultimately, with Booster 4 work ramping back up and the zenith of orbital pad construction activity now likely behind SpaceX, preparations for major Super Heavy testing will hopefully resume. SpaceX has yet to perform a full Super Heavy wet dress rehearsal (WDR; fully filling a rocket’s tanks and performing a launch countdown) or fire up more than three Raptors on a booster or ship prototype. With any luck, that will finally change in the final months of 2021.

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 Cybercab and Robotaxi’s real advantage won’t be the ride service

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Concept art of a Tesla Cybercab in Las Vegas Strip as rendered via Grok

For a century, the car has asked the same thing of its owner, which is basically to pay attention. Even the best ride-hailing app like Uber or Lyft only moved the problem into someone else’s hands. You stopped driving, but you still sat in a stranger’s car, while half listening, and wondering whether to take a phone call in the car without being rude. The Cybercab has no wheel, no pedals and no driver. With Grok @bot now live inside it, it becomes something else entirely, and I think that matters more than the fleet count that everyone is tracking.

Grok @bot is an agent, not a voice assistant. A rider signs in once, and from then on can say what they need and watch it happen. Order dinner from a favorite restaurant. Fill the grocery cart. Move money, answer email, adjust a calendar, push a work project forward. Tesla engineer Yun-Ta Tsai confirmed it is enabled across every Cybercab and the rest of the Model Y fleet, and Tesla’s own pitch is that Full Self-Driving handles the commute while Grok handles the errands.

Think about what that does to a thirty minute ride. Uber sells you a trip, while Waymo sells you the same trip in a more private setting. Tesla is selling the thirty minutes themselves, returned to you with an assistant attached. Errands that used to eat a Saturday get done between pickup and drop off. The ride stops being dead time between two places and becomes a place of its own.

Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

Best of all, your Bots follow you into any Cybercab, and presumably your own Tesla, then logs you out automatically when you step out. Anyone can bolt a chatbot onto a screen, but much harder to own the vehicle, the autonomy stack and the assistant at once. It also quietly ties SpaceX’s Super Intelligence business to Tesla’s fleet, after Tesla converted its xAI stake into SpaceX equity. The relationship between those two companies is getting harder to describe as separate.

This is also where the hard questions start, because an agent that can spend your money in a vehicle other people also ride in needs some answers. How does it handle a voice it shouldn’t trust? What gets recorded, who can see it, and for how long? What happens when a rider leaves halfway through a task?

If Tesla gets those answers right, the scoreboard changes. We have been counting Cybercabs and wait times. The more telling number may be what riders accomplish per trip. That is data almost no one else will ever have, and it is the real reason to watch Grok @bot.

What do you think? Leave me a comment.

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Why Elon Musk’s target date for buying an Optimus robot is harder than it sounds

Musk says China’s magnet export ban cost Optimus months, and robot hands remain shockingly hard.

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Concept rendering of Tesla Optimus in mass production

Elon Musk says China’s export curbs on magnets used in electric motors set back Tesla’s Optimus program by two to three months, and that the robot’s hands remain the hardest part of the project. He made the comments Saturday during a live interview with Tesla Owners Silicon Valley at the X Takeover event at Giga Texas, in front of roughly 2,000 attendees. The Optimus discussion begins around the 49 minute mark of the stream.

On the hands, Musk was blunt and noted that a general purpose humanoid needs fine motor skills that are “incredibly difficult to get right. Shockingly difficult,” he said in the interview. He pointed to a problem he says no one has demonstrated yet: “One of the hardest things also generally is to do precision and force at the same time,” such as driving a small self tapping screw into wood. Touch sensors add another layer, since it is “actually kind of hard to get touch sensors that elastically deform and can handle high cycle life and it won’t just break after a few thousand cycles.”

He also took aim at rival robot videos. “Any complicated looking robot demo, it’s a canned demo. It’s not real,” Musk said, adding that real AI means showing a robot something it has never seen and watching it still cope, the way FSD handles a city it has never driven.

Musk expects the Optimus ramp to be slower than a new vehicle production ramp. “The initial part of that S curve of production ramp is going to be very slow at the beginning,” Musk said, partly because “unlike cars, there’s no pre existing supply chain for robot stuff.” That echoes his July reply on X that Optimus production “will be extremely slow at first, as everything is new.”

The magnet disclosure puts a number on a problem Musk first raised in 2025. He said China “prevented the export of magnets for use in electric motors” and that it “set back the Optimus program by like two or three months.” Then he added: “We had robots with no arms.” Tesla’s fix is to bring the supply chain home. “You’ve got to be able to make all the parts domestically,” he said. Teslarati reported in April 2025 that Musk tied the issue to permanent magnets in the arm actuators, where motors have to be as small as possible.

Tesla Optimus V3 hand and arm details revealed in new patents

Production is moving regardless, with a reported internal goal of more than 1,000 a week by the end of 2026. Teslarati recently covered how Tesla is certifying supply partners in China for Optimus parts, while the company’s hand design has been the subject of new patent filings.

Musk has said he wants Optimus available to the public by late 2027, though Tesla has not confirmed that date or published updated production figures.

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Investor's Corner

Elon Musk drops a Thanksgiving hint about Starship’s biggest test yet

Elon Musk says Starship Flight 15 will try to catch the ship itself, a first.

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Elon Musk says SpaceX’s next Starship flight will try something nobody has done before, by catching the ship itself. Speaking to roughly 2,000 people at the X Takeover event at Giga Texas on Saturday, Musk said Flight 15 is about four to six weeks away and “probably launches a little bit before Thanksgiving, is my guess.”

That is a slip from earlier reporting, which had pointed to a launch as early as October 19. Musk explained why the date keeps moving. “We’re making a bunch of improvements to the rocket between every flight,” he said, adding that there are often hundreds, sometimes thousands, of small changes. This time the list is short, “but some of them take a fair bit of work and we’ve got to go inside the tank to make some of these changes.”

“We’re going to try to catch the ship, which is a super big deal,” Musk said. “If we do so, that’ll be the first time that there’s been full recovery of an orbital class rocket.” SpaceX has already caught the Super Heavy booster with the tower’s mechanical arms, and has talked about catching the ship since late 2025, but the upper stage has never been caught.

Musk also laid out what comes after. “The next big milestone would be to refly both the booster and the ship,” he said, describing a Flight 16 where “all parts of an orbital rocket are reflown.”

The reason SpaceX wants this comes down to cost and cadence. Every Starship ship so far has ended its flight in the ocean, and SpaceX expects most of those water landings to end in fireballs. A ship that returns to Starbase intact can be inspected and flown again. SpaceX’s IPO filing, says Starship V3 is designed to deliver 100 metric tons to orbit in a fully reusable configuration, that SpaceX aims to cut the cost to reach orbit by 99% or more versus the historical average, and that tower catches should allow “multiple launches per day.”

The payoff goes beyond cheaper launches. The next generation Starlink V3 satellites are too large for Falcon 9 and can only fly on Starship, which can carry up to 60 per flight. Flight 14 on September 28 deployed the first 26 of them after Starship reached orbit despite an early engine shutdown, as Teslarati reported. Musk blamed engine computer software, and said the heat shield “was extremely robust,” which he claimed in August had solved Starship’s biggest challenge.

NASA’s Moon plans depend on the same capability. NASA’s inspector general has described a lander mission that needs a propellant depot in low Earth orbit and more than 10 tanker flights, with SpaceX targeting one tanker launch every six days. That schedule only works if ships and boosters come back fast and fly again. Also, ship to ship propellant transfer has not been attempted yet.

One interesting hurdle yet to be explored is bringing the ship back to the launch site, with reentry over land, which will undoubtedly come with a lot of aviation safety reviews.

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