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Elon Musk says SpaceX’s second Starship booster prototype is almost finished

Starship SN16 and Booster 3, May 28th. (Elon Musk)

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5 years ago

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SpaceX CEO Elon Musk says that the second Starship booster prototype is “almost done” and has revealed that work on the first flightworthy booster has yet to begin.

For unknown reasons, SpaceX has recently changed the naming scheme for Starship and Super Heavy boosters. The booster SpaceX is currently assembling in Boca Chica has been referred to as “Booster 2” by Musk himself but, according to NASASpaceflight, is internally known as Booster 3 or B3, replacing its former Booster Number 3 (BN3) designation.

Regardless, SpaceX began stacking the Super Heavy booster prototype now known as B3 in mid-May. Around six weeks later, 23 or 24 rings have been stacked to create a partially finished prototype 9m (~30 ft) wide and approximately 42m (~140 ft) tall.

Just like Super Heavy ‘pathfinder’ BN1, which was scrapped almost the instant it reached its full height last March, Booster 3 appears to destined to stand 36 rings – 65m (~215 ft) – tall once complete. While drastically oversimplifying the process of vertically assembling the largest rocket booster ever built, that means that Super Heavy B3 is just shy of two-thirds (~65%) complete.

By simply averaging the time it’s taken for SpaceX to stack B3 to a height of 42 meters, the booster could reach its full height around three weeks from now (July 15th, give or take a week). For the most part, the most challenging and unfamiliar parts of Super Heavy B3 manufacturing and assembly have already been completed. Relative to Starship, which SpaceX has now built more than half a dozen prototypes of, Super Heavy is just a stretched Starship with no flaps, no nosecone, a far more complex engine section, and a forward dome section that needs to support car-sized grid fins.

Super Heavy’s larger propellant tanks also require a methane transfer tube – used to carry methane through the booster’s lower liquid oxygen tank – more than twice as tall as anything built for Starship. By all appearances, that ~35m (~115 ft) tall transfer tube has already been safely installed inside B3’s incomplete tanks. Around June 14th, B3’s lower two-thirds were effectively completed when its LOx tank stack was mated to the booster’s 29-Raptor engine section.

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Super Heavy Booster 1 reached its full height in March 2021 and was summarily scrapped a few weeks later. (NASASpaceflight – bocachicagal)

Outfitted with complex structural modifications to support massive grid fins and the first advanced ‘hot gas’ maneuvering thrusters ever spotted in public, Booster 3’s forward dome is already in the process of being welded to a stack of three steel rings. Once complete, the rest of Super Heavy B3 integration is fairly simple as far as rocket assembly goes and will require four more welding operations. Like BN1, there’s a good chance that SpaceX will mate Booster 3’s upper (methane) tank separately and then install the ~24m (~80 ft) tall, 13-ring section on top of the LOx stack to effectively complete the booster’s main structure

Of course, after the structure is complete, SpaceX will still need to finish plumbing, wiring, and generally outfitting a Super Heavy booster for the first time ever. Finally, while it remains to be seen just how finished B3 will actually find itself before heading to the launch pad, that process could also involve installing and testing four massive steel grid fins and, most importantly, up to 29 Raptor engines – a figure only beaten by the Soviet Union’s ill-fated N1 rocket.

Perhaps most significantly, Musk also revealed that B3 is not the Super Heavy booster assigned to Starship’s first orbital launch attempt, meaning that SpaceX will have to complete Booster 3 testing and build Booster 4 before that orbital test flight can occur. Given that Booster 3 assembly is on track to take more than nine weeks, Starship’s first orbital launch attempt is thus unlikely to happen before late August or September.

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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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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

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16 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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