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SpaceX stacks first Super Heavy, creating largest rocket booster ever built

SpaceX has stacked its first Super Heavy booster, effectively completing the largest rocket booster ever assembled. (Elon Musk)

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For the first time ever, SpaceX has stacked a Super Heavy tank section to its full height, effectively completing assembly of the largest rocket booster ever built.

While a good amount of work still remains to weld the two halves together and connect their preinstalled plumbing and avionics runs, those tasks are largely marginal and will tweak the massive steel tower that’s now firmly in one piece. Comprised of 36 of the steel rings also used to assemble Starships, the first Super Heavy prototype – serial number BN1 – will stand roughly 67 meters (220 ft) tall from the top of its uppermost ring to the tail of its soon-to-be-installed Raptor engines.

At that height, Super Heavy BN1 is just 3 meters (~10 ft) shorter than an entire two-stage Falcon 9 or Falcon Heavy rocket – the second and third tallest operational rockets today. Of course, Super Heavy is just a booster and SpaceX says the rocket will stand at least 120m (~395 ft) tall with a Starship upper stage and spacecraft installed on top, easily making it the tallest (and likely heaviest) launch vehicle ever assembled.

Notably, Super Heavy BN1 isn’t fully representative of the boosters that will support Starship’s first orbital launch attempts. For unknown reasons, SpaceX appears to have forgone the installation of any kind of landing legs on the first pathfinder and prototype. CEO Elon Musk has expressed a desire to avoid the need for legs entirely by catching Super Heavy boosters (and possibly even Starships) with a tower outfitted with giant arms, but it’s virtually impossible to imagine that such a wholly unproven recovery mechanism will be ready for full-scale testing – let alone operational use – later this year.

https://www.nasaspaceflight.com/2021/03/starship-sn11-spacex-orbital-flight-summer/
A Starship thrust dome sits to the left of Super Heavy BN1’s thrust dome. (NASASpaceflight – bocachicagal)

First reported by NASASpaceflight and later confirmed by Musk himself, SpaceX hopes to be ready to begin orbital Starship launches as early as July 2021, just four months from now. Per NASASpaceflight, that first launch attempt will nominally use Super Heavy booster BN3 and Starship SN20. Super Heavy BN1 is expected to remain grounded, serving as a testbed for inaugural pressure and proof tests, as well as one or several possible Raptor static fires (Update: confirmed by Musk).

If that process goes according to plan, Super Heavy BN2 will pick up where BN1 leaves off and attempt at least one short hop test, among other qualification tasks. In the interim between that feat and Super Heavy BN3’s launch preparations, it’s safe to assume that either BN2 or BN3 will support some kind of iterative static fire test campaign similar to what SpaceX once did with Falcon 9, gradually building up from tests with a half-dozen or so engines to static fires with 20 or more – possibly up to and including a full complement of 28 Raptors.

SpaceX installs BN1’s engine section on a custom workstand heavily reinforced for an entire Super Heavy booster. (NASASpaceflight – bocachicagal)

The first of its kind, booster BN1’s ‘thrust donut’ – a donut-shaped plate for the rocket’s center cluster of Raptor engines to attach to – appears to have been outfitted with hardware for four engines, suggesting a ceiling for static fire tests. It’s unclear when Super Heavy will roll to the launch pad for testing but it’s safe to say that SpaceX probably wont wait long after Starship SN11 is done with its high-altitude launch campaign. Stay tuned for updates!

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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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Tesla’s Roadster appearance at SpaceX has merger watchers talking

Tesla’s next generation Roadster was spotted at SpaceX’s Hawthorne headquarters, two weeks after its unveiling.

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The Roadster’s rear wing, one of the aerodynamic elements Tesla pairs with a fan-based downforce system. (Image: Tesla)

Tesla’s next generation Roadster turned up at SpaceX’s headquarters in Hawthorne, California on Wednesday, less than two weeks after the car flew off a ramp at its unveiling in Texas.

Photos shared on X by SpaceX Engineer (@DeannaRiceSPCX) show the new Roadster parked outdoors beside the famed Falcon 9 that stands outside company headquarters at the corner of Crenshaw Boulevard and Jack Northrop Avenue. Rocket B1019 was the first orbital-class booster ever to land after a launch on December 21, 2015 after it sent 11 Orbcomm satellites to orbit and then flew back to Landing Zone 1 at Cape Canaveral, which would be the first landing in what became SpaceX’s reusable rocket program. SpaceX chose not to fly it again. After a test fire in Florida, the booster was shipped to Hawthorne and raised upright as a permanent monument in August 2016, as Teslarati reported at the time. Putting the Roadster, which flies on SpaceX cold gas thrusters, next to the rocket that started SpaceX’s landings is symbolic in itself.

The Thrust and Rocket versions of the Roadster use cold gas thrusters fed by composite overwrapped pressure vessels, the same type of tank SpaceX flies on Falcon 9, and Elon Musk described the car as the work of Tesla and SpaceX engineers working together. Tesla lists 0 to 60 mph in under 0.9 seconds for Thrust and under 0.59 seconds for Rocket, while the base Performance model relies on a fan and ground sealing system for grip, as Teslarati detailed in its breakdown of the three Roadster configurations.

Tesla has kept the car in the spotlight since the October 15 event near Waco. Last week, the company posted a video of the Roadster’s fighter jet inspired cockpit, including a Track Mode screen with a “Thruster · 5,500 PSI” readout, which we covered in our look at the Roadster’s center display. Musk also said owners will be able to ask the car to perform the stunts autonomously, and promised a looping track at Tesla’s Texas headquarters.

The visit comes as special committees at Tesla and SpaceX weigh a possible merger, a step Musk confirmed on SpaceX’s third quarter earnings call. The Roadster, built on SpaceX hardware, has become one of the clearest examples of the two companies already building products together.

Musk said at the unveiling that Roadster production will begin in 2028. Reservations are open with a $50,000 payment, Thrust is listed as a limited release and Rocket is invite only. Tesla says the car is not approved for public road use.

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Verizon, AT&T and T-Mobile are trying to shut Starlink out before FCC vote

AT&T, Verizon and T-Mobile want 290 MHz cut from an FCC satellite plan before Thursday.

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Starlink D2D direct to device vs Verizon, AT&T (Concept render by Grok)

AT&T, Verizon and T-Mobile are asking the Federal Communications Commission to pull nearly 300 MHz of spectrum out of a proposal that would let satellite companies like SpaceX offer cell service directly to ordinary phones. The request lands one day before the agency votes on it.

The FCC will vote Thursday, October 29, on a notice of proposed rulemaking that would make an additional 482 MHz available for direct to device service, expanding the number of eligible bands from five to 13, according to the FCC fact sheet. It would also scrap the rule requiring a satellite operator to lease spectrum from carriers, replacing it with a certification that the operator has coexistence agreements in place or holds the terrestrial license itself.

That second path matters for SpaceX. As Teslarati reported earlier this month, SpaceX agreed to buy Grain Management’s nationwide 800 MHz portfolio to turn Starlink Mobile into a full US carrier, adding to the spectrum it already bought from EchoStar.

The carriers want two bands removed, 2.5 GHz and 3.45 GHz, which make up 290 MHz of the 482 MHz on the table. Through industry group CTIA, they argued that about 300 million users depend on those bands and that satellite operations in them are not technically feasible. T-Mobile, which calls 2.5 GHz the foundation of its Ultra Capacity 5G network, said in its own filing that satellite interference could wipe out up to 96% of a cell site’s uplink coverage area and cut uplink speeds by 88% to 99%.

Executives from all three carriers met with FCC staff on October 20, and T-Mobile CEO Srini Gopalan met separately with FCC Chairman Brendan Carr. T-Mobile’s role stands out because it is still SpaceX’s US launch partner for Starlink Mobile. The three carriers have also teamed up on their own satellite joint venture to pool spectrum, a move widely seen as a response to Starlink.

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SpaceX is asking for the opposite. In an October 23 filing after meetings with FCC staff and commissioners’ offices, the company asked regulators to add the 902 to 928 MHz band to the proposal. “Doing so now saves time later,” SpaceX wrote. The company also asked the FCC to modernize interference rules and align satellite deployment requirements with those for terrestrial cell networks, saying the goal is to let satellite and ground networks work together so Americans stay connected wherever they are.

The carriers have not been shy about how they view SpaceX as a competitor. On Verizon’s third quarter earnings call Monday, its chief executive said Starlink Mobile “just can’t compete with a terrestrial network” and estimated SpaceX would need four to six years and $300 billion to $500 billion to build a full US carrier network.

Thursday’s vote will not settle which bands survive. Adopting the notice opens a public comment period, with final rules to come later in the proceeding. The FCC already considered and rejected 2.5 GHz for satellite coverage once, in 2024. SpaceX also is not the only satellite player watching: the FCC approved Amazon’s $11.6 billion acquisition of Globalstar on October 27, giving its planned direct to device fleet its own mobile satellite spectrum.

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Tesla Semi catches fire in California: what we know

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Credit: KTVU

A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.

The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.

There were no injuries reported.

The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.

However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.

At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.

The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.

The truck’s driver said that the Semi caught fire, but he did not have an explanation.

An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.

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