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SpaceX Super Heavy booster returns to launch pad after major repairs

Booster 7 has returned to the orbital launch site after suffering damage a few weeks prior. (NASASpaceflight - bocachicagal)

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SpaceX has returned its newest Super Heavy to Starbase’s orbital launch site (OLS) after rapidly repairing damage the booster suffered during its first round of testing.

Super Heavy Booster 7 (B7) left the High Bay it was assembled in for the first time on March 31st and rolled a few miles down the road to nearby Starship launch and test facilities on a set of self-propelled mobile transporters (SPMTs). On April 2nd, the roughly 67-meter-tall (~220 ft; 69m w/ Raptors) rocket was installed on top of Starbase’s lone orbital launch mount (OLM), setting the stage for crucial qualification testing.

The start of that process was exceptionally successful. On April 4th, after a smooth launch mount installation, SpaceX quickly filled Booster 7’s propellant tanks with a relatively benign cryogenic fluid (liquid nitrogen, liquid oxygen, or both) to simulate the thermal and mechanical characteristics of real flammable propellant. Despite the fact that the test marked the first time SpaceX had fully filled a Super Heavy prototype’s tanks, Booster 7 sailed through the ‘cryoproof’ without any obvious issue.

On April 8th, SpaceX moved Super Heavy B7 from the orbital launch mount to a structural test stand that had been installed and modified just a few hundred feet away in the weeks prior. This is where Booster 7’s near-perfect start to qualification testing took a bit of a turn. Booster 7 is only the third full-size Super Heavy prototype SpaceX has tested since July 2021. Like Booster 3 and Booster 4 before it, Booster 7 features some major design changes that ultimately make the prototype a pathfinder, necessitating extensive qualification testing.

To name just a few of the changes, Super Heavy B7 is the first booster fitted with a 33-engine puck and the first finished Starship prototype of any kind designed to use new Raptor V2 engines. With all 33 engines installed and operating a full thrust, Booster 7’s entire structure – and its aft thrust section especially – would be subjected to around 40% more thrust and stress than Booster 4, which indirectly completed structural testing with the help of a sacrificial test tank. Beyond differences in thrust and mechanical stress, Booster 7 is also the first Super Heavy to reach the test stand with secondary ‘header’ tanks meant to store landing propellant.

It’s unclear if those header tanks were fully filled and drained during Booster 7’s cryoproof, but they would not be quite as cooperative during a different kind of cryogenic testing on the structural test stand. The stand SpaceX modified specifically for Super Heavy B7 was outfitted with 13 hydraulic rams to simulate the full thrust of the booster’s central Raptor V2 engines – up to almost 3000 tons (~6.6M lbf) compared to Booster 4’s ~1700 tons (~3.7M lbf) with a smaller cluster of nine engines.

Implosion at the Structural Test Stand

After a few false starts and minor tests on the stand, Booster 7 finally managed some significant testing on April 14th. Judging by the rhythmic shattering of ice that built up on Super Heavy’s tanks, the test stand was able to simulate the thrust of Raptors to some degree and subject the booster to major mechanical stress that was felt from tip to tail. Within a few days, Booster 7 was removed from the test stand and returned to the high bay on April 18th. Around April 21st or 22nd, an image was leaked showing extensive damage inside Booster 7, confirming that the Super Heavy’s test campaign had been forced to end prematurely.

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A leaked image looking up inside B7’s LOx header tank after testing. Above, B7’s aft section and LOx header before the booster was fully assembled.

Right away, the damage shown in the photo hinted at an operational failure, meaning that mistakes made by the rocket’s operators may have been more to blame than a possible design flaw. The photo shows a short portion of B7’s liquid methane (LCH4) transfer tube that runs through the booster’s new liquid oxygen (LOx) header tank, which itself sits inside Super Heavy’s main LOx tank at the aft end of the rocket – a tube inside a small tank inside a large tank, in other words. Super Heavy’s LCH4 transfer tube generally does what it says, allowing methane to safely fly down through the main LOx tank and fuel up to 33 Raptor engines. At full thrust, that tube would need to supply around 20 tons (~45,000 lb) of methane per second.

However, on top of merely transferring methane through the oxygen tank, Booster 7 introduced a design change that allows some or all of that tube to change functions and become a header tank mid-flight. That would require a system of valves that could seal off the main LCH4 tank once it was emptied, turning the transfer tube into a sort of giant steel straw filled with enough LCH4 to fuel Super Heavy’s boost-back and landing burns.

The damaged transfer tube in the leaked photo of Booster 7 doesn’t look that unlike what one might expect to see if they sucked through one end of a straw while blocking the other end, collapsing the center. Translated to the scale of Super Heavy, after an otherwise successful day of structural testing, SpaceX operators may have accidentally closed or opened the wrong valves while draining the booster’s transfer tube of liquid oxygen or nitrogen. As the heavy liquid drained from the tube, a lack of pressure equalization could have quickly drawn a vacuum and caused the tube to implode.

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On April 29th, a SpaceX fan turned analyst published an analysis that convincingly pinpointed the moment Booster 7’s transfer tube collapsed. Simultaneously, because it showed that the transfer tube likely imploded during detanking, the analysis more or less confirmed the above speculation that the failure had been caused by a degree of operator error or poor test design. Of course, it’s possible that a hardware or software design flaw contributed to or caused the anomaly or that something like a pressure differential in the LOx header tank and LCH4 header tube could also explain the damage, but the accidental formation of a vacuum during detanking is arguably the simplest (obvious) explanation.

After the image of the internal damage leaked, the immediate consensus among fans and close followers was that Booster 7 was beyond repair. Instead, SpaceX appears to have proven those assumptions wrong and somehow managed to repair the upgraded Super Heavy to the point that it was worth testing again less than three weeks after returning to the high bay. On May 6th, B7 was rolled back to the launch site and installed, for the second time, on the orbital launch mount.

Prior to the failure, the general expectation was that SpaceX would begin installing Raptor V2 engines as soon as Booster 7 passed structural testing. It remains to be seen if SpaceX wants to repeat Booster 7’s cryoproof or structural testing to ensure that its quick repairs did the job before proceeding into static fire testing as previously planned. Nonetheless, hope lives on for the Super Heavy prototype and new test windows have been scheduled from 10am to 10pm on May 9th, 10th, and 11th.

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 Full Self-Driving v14.3.7 early review: FSD saved me from an accident

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Credit: Teslarati

Tesla released Full Self-Driving version 14.3.7 yesterday, and after about 90 miles of testing today, it is evident there are some definite fixes from version 14.3.6, which I wrote about last week and called a regression.

Within the first 40 minutes of my drive on v14.3.7, it saved me from getting into an accident with an unaware Dodge Charger driver, and some of the things Tesla seemed to miss in v14.3.6 were definitely improved. All in all, the release so far has some really great performance, and I’m looking forward to testing it further.

For now, here’s everything I noticed with v14.3.7:

Overall Improvement

Just generally speaking from a ride perspective, this was a really great experience. A lot of the hesitancy I experienced on v14.3.6 was gone. There were no instances of brake-stabbing, wheel-jerking, or any uncertain or unconfident movements. It was void of anything that I felt made it timid with v14.3.6.

The one thing I do hope to see down the road is a smaller need to adjust Speed Profiles so often. Because Tesla calls FSD “Supervised,” I’m okay with needing to hit the scroll wheel a few times a drive.

However, I hope that things can be incrementally improved upon with speed. Sometimes it’s too fast; other times it’s too slow. It’s a difficult thing to hone in and refine, but I hope it eventually gets there.

I didn’t notice any significant left lane camping or any behaviors that were completely out of line. I am hopeful that this opinion does not change, but after driving a few days with this version and putting it in a variety of different situations, you are exposed to more behaviors, some of which are not necessarily what I’d prefer.

The big things to notice, at least in my experience thus far, are that the major issues with previous versions — meaning the braking stabbing and wheel jerking — simply weren’t there. That’s enough to already consider this progress compared to .6.

Manual Signal Override is More Responsive

On .6, I had quite a few issues with FSD ignoring my manually input turn signals. If Tesla wants to call it “Supervised,” then the car should not ignore any input the driver gives. If I touch the accelerator on FSD, the car speeds up.

The car did a great job of obeying my turn signals when I wanted it to change lanes, which is welcome.

Parking Lot Performance

Before .6, I traditionally took over in nearly every parking lot my car entered, because I knew it would not park somewhere that I wanted, and usually, it was just a tad too timid in this setting.

The one bright spot of .6 was how well it handled parking lots. This continued with v14.3.7:

 

I’m always really happy to see progress at all, but once parking preferences come to FSD, as long as this performance is still around, that could potentially be the biggest improvement I’ve seen in FSD in the year I’ve been using it personally on a daily basis.

Full Self-Driving Averts Disaster

A Dodge Charger changed into my lane without checking if I was there, running me off the road. FSD made the initial avoidance maneuver; I grabbed the wheel out of instinct, looked in my side mirror to ensure I had nobody following closely behind, hit the brake, and straightened the car back up to avoid a curb:

There have been quite a few responses to this video stating that I should never have grabbed the wheel. To be honest, I really wish I had not done so, because I do believe FSD would have avoided any sort of collision with anything, including the car or the curb.

However, this was the first time I had ever been this close to being hit while using FSD. My natural reaction was to take over. I think if I had had something like this happen before, my reaction might have been different.

Hitting the brake avoided hitting the curb, while FSD swerved to avoid the car. My concern after the car was clear of my front end was the curb. All in all, I’m really happy with how things turned out, and I think anyone could be a critic of how I handled it. I only had a split second to really make a decision, and thankfully, any damage was avoided.

It is clear FSD managed to avoid the car coming down before I was able to. I truly credit FSD for avoiding the collision.

What Needs to Improve

Better Recognition of Potholes, Uneven Roads, Sharp Changes in Roadway/Bumps

On Friday, my Fianceè and I were in the car, and FSD was driving us. We crossed over a roadway that has a traffic light, and FSD was traveling at 40 MPH on Standard, 5 MPH over the speed limit. Everything was more than reasonable.

However, the road we were crossing at the light has a major bump both as you start and finish crossing it. Without a speed reduction, your car can go airborne. The Tesla did just this on Friday on v14.3.6; it was an uncomfortable bounce that pretty much confirmed I would not ever let FSD go over again unless we were sitting at that intersection when there is a red light.

I even tried scrolling down into Sloth quickly, but I ended up just taking over:

A few people have said it remains related to the vision-based approach and its difficulty comprehending 3D. This is a huge issue because this can cause serious damage at certain speeds.

Navigation

Nothing new here. I still turn off “Online Routing” quite frequently to get the car to take logical routes from time to time.

Auto Wipers

Auto Wipers are just plain bad. I really hope Tesla just uses a rain sensor. I thought they had improved at one point, but I still get dry wipes, Speed 4 on a drizzle, and Speed 2 on a steady rain. In reality, these should be switched.

You can watch our full review of Tesla Full Self-Driving v14.3.7 below:

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SpaceX’s biggest test yet arrives this week and it’s not a rocket launch

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SpaceX will report second quarter results after the market closes on Tuesday, August 4, marking the first time the company has opened its books to the public since its record IPO in June. Management will host a live audio only webcast at 4:30 p.m. ET, streamed on X, with no dial in option.

The debut carries more weight than a typical first quarter as a public company. Two trading days after the release, on August 6, the first tranche of SpaceX’s lockup expires, freeing roughly 911.5 million insider and employee shares, worth well over $100 billion at current prices and the largest such release in Wall Street history. A second, larger tranche tied to the stock trading 30 percent above its $135 IPO price never triggered, since shares have spent most of July trading below that price.

Wall Street’s models point to revenue near $6.9 billion for the quarter, up sharply from the $4.69 billion SpaceX reported in the first quarter, with a narrower per share loss than the $1.27 posted three months earlier, according to estimates compiled by Motley Fool. Those numbers will be the first look at how SpaceX’s three segments, Starlink, launch and AI, are performing independently.

SpaceX scores another massive Pentagon deal to support military satellites

Investors heading into the call have a specific list of questions. How many net new Starlink subscribers did SpaceX add after ending March with 10.3 million, and is average revenue per user holding up as the service expands into lower income markets. How much of the AI segment’s revenue reflects contract signings with Anthropic, Google and Reflection AI this year, deals that combined could annualize to nearly $28 billion if fully ramped. Whether capital expenditures, which nearly doubled in the AI segment alone between 2024 and 2025, are still accelerating or starting to plateau. And whether management offers any forward guidance at all, something SpaceX has never done publicly.

The report will also land days after Elon Musk publicly denied a Wall Street Journal report describing internal planning to separate Tesla’s China business ahead of a potential Tesla-SpaceX merger. Whether Musk or SpaceX executives address that speculation on the call, even indirectly, maybe something investors will be listening for on Tuesday.

As Teslarati reported after Musk’s own warning to short sellers last week, the CEO has made clear he expects skeptics to be proven wrong over time. Tuesday will be the first chance for the numbers themselves to make that case.

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SpaceX’s Starship just got filmed by its own cargo

SpaceX released new footage of Starship in space captured by the Starlink satellites it deployed.

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SpaceX released a new video Friday evening showing Starship from an angle showcased by its own Starlink satellites, watching the rocket drift away in orbit.

The 65 second clip, posted on X, stitches together footage from four cameras mounted on a single Starlink V3 satellite. It opens with a close view of Starship’s 171 foot upper stage, still catching sunlight, then pulls back as the two spacecraft separate.

The footage comes from Starship’s 13th flight test, which launched July 24 from Starbase after a scrubbed attempt and an abort caused by an engine issue the week before. When Flight 13 finally flew, it carried the first batch of functional Starlink V3 satellites Starship has ever deployed, twenty of them, with six equipped with cameras meant to scan the ship’s heat shield during reentry.

Flight 13 checked most of its boxes. Starship deployed all 20 satellites, relit a Raptor engine in space, and splashed down softly in the Indian Ocean off Western Australia. Musk’s longer term plan calls for a Starlink V3 constellation of 100,000 satellites, according to a recent FCC filing, with Starship as the only vehicle capable of launching them at the volume that requires. Each Starship flight is designed to carry up to 60 V3 satellites once the vehicle reaches routine service, well beyond what Falcon 9 can carry in a single mission.

Starship is next expected to fly with an attempt at catching the ship itself with the launch tower’s mechanical arms, a maneuver SpaceX has so far reserved for the Super Heavy booster.

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