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SpaceX tests Starhopper’s maneuvering thrusters ahead of inaugural flight test

On July 22nd, SpaceX technicians and engineers spent the evening testing Starhopper's nitrogen gas maneuvering thrusters, taken straight off of Falcon 9. (NASASpaceflight - bocachicagal)

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Late at night on July 22nd, SpaceX’s South Texas team of technicians and engineers were busy testing a small but critical component of Starhopper, a testbed and low-fidelity Starship prototype meant to attempt its first untethered flight test as early as July 24th.

Monday evening’s testing centered around Starhopper’s cold gas nitrogen thrusters, multi-nozzle assemblies that appear to have quite literally been taken off of flight-proven Falcon 9 boosters. For Starhopper, they will act in a similar – albeit significantly reduced – fashion, serving to control the giant steel prototype’s attitude and augment its lone Raptor engine’s own thrust vectoring (i.e. steering) capability.

Although SpaceX has never released official numbers for the thrust of the cold gas thrusters used on Falcon 9 boosters and upper stages, it’s safe to say from their performance that the low-efficiency nitrogen thrusters produce roughly 5 kN (~1100 lbf) of thrust, perhaps up to 10+ kN. For an almost empty Falcon 9 booster, this translates to extremely rapid (sub-10s) flip maneuvers during return-to-launch-site (RTLS) landings.

At the same time, Falcon boosters have two sizes of cold-gas thrusters, with much larger high-performance (>10 kN) pods – located on the larger of the booster’s two raceways – focused on settling the rocket’s propellant after recovery-related coast periods. A duo of smaller 3-axis pods situated on the outside of the interstage serve as true attitude control system (ACS) thrusters, precisely pointing, flipping, and orienting boosters during vacuum operations and partially augmenting grid fin control authority during the late stages of landings. Despite their much smaller size, they still pack an impressive punch and are famous for almost saving tipping Falcon boosters during early (failed) landing attempts.

Starhopper, meanwhile, is dramatically larger than the Falcon 9 and Heavy boosters its tacked-on ACS thruster pods were designed for. It’s hard to know for sure but safe estimates peg the testbed’s dry mass somewhere around 50-75 metric tons (110,000-165,000 lb) thanks to the thick steel it was constructed out of. In other words, Starhopper likely weighs at least twice as much as an empty Falcon 9 booster (~25 metric tons).

To alleviate this mismatch, SpaceX arrived at a hilariously simple and cheap solution: install double the number of grave-robbed Falcon 9 thruster pods on Starhopper and voila! It was that duo of thruster pod pairs that were tested on July 22nd, visibly producing four distinct jets of pressurized nitrogen gas. Whenever Starhopper gets to hopping, those ACS thrusters should help the rocket precisely control its rotation, attitude, and – to a lesser extent – translation, hopefully helping to ensure a successful inaugural hover and divert test.

Scheduled to occur no earlier than Wednesday, July 24th, SpaceX plans to deconflict Cargo Dragon’s CRS-18 launch and Starhopper’s hover test, meaning that they will not happen simultaneously. In the ~70%-likely event that bad Florida weather delays CRS-18 to Thursday, July 25th, the road before Starhopper will be clear for an attempted hover on the 24th. Additionally, also reported first by NASASpaceflight.com, the test is expected to involve a divert, meaning that Starhopper will lift off, hover roughly 20m (65 ft) off the ground, and then carefully travel a few hundred feet East to a recently-constructed concrete pad for a soft landing.

This divert was tacitly confirmed by the arrival of a robotic transport mechanism, already used once before to move Starhopper from its build site to the launch pad. If the divert goes as planned, the transport equipment will be used to return Starhopper to its spartan launch mount and ground support equipment (GSE) umbilicals.

If Starhopper survives and Raptor SN06 performs nominally, it’s all but certain that the testbed rocket will be put through a series of increasingly ambitious test flights over the coming months – at least before SpaceX’s first higher-fidelity “Mk 1” Starship prototypes begin their own flight tests. According to CEO Elon Musk, those Starship test hops and flights could begin as few as 2-3 months from now – September or October 2019.

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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 recalls 6,197 Cybertrucks for light bar adhesive issue

On October 20, Tesla issued a voluntary recall of the impacted vehicles and has identified 619 warranty claims and just a single field report that is related to the issue. 

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Credit: Francisco Garcia (via Greggertruck on X)

Tesla has recalled 6,197 Cybertrucks for a light bar adhesive issue that was utilized by Service to install the aftermarket part.

According to the National Highway Traffic Safety Administration (NHTSA), impacted vehicles may have had the light bar “inadvertently attached to the windshield using the incorrect surface primer.”

Tesla identified an issue with the light bar’s adhesion to glass back in February and worked for months to find a solution. In October, the company performed chemical testing as a part of an engineering study and determined the root cause as the BetaPrime primer it utilized, figuring out that it was not the right surface priming material to use for this specific application.

On October 20, Tesla issued a voluntary recall of the impacted vehicles and has identified 619 warranty claims and just a single field report that is related to the issue.

The component is manufactured by a Romanian company called Hella Romania S.R.L., but the issue is not the primer’s quality. Instead, it is simply the fact that it is not the correct adhesive for this specific type of application.

Tesla says there are no reports of injuries or deaths due to this issue, and it will be resolved. In the 473 report that the NHTSA released this morning, Tesla said:

“At no charge to customers, Tesla will inspect the service-installed optional off-road light bar accessory for delamination or damage and if either is present, replace the light bar with a new light bar adhered with tape and a positive mechanical attachment. If no delamination or damage is present, Tesla will retrofit the service-installed optional off-road light bar accessory with a positive mechanical attachment.”

This is the third recall applied to Cybertrucks this year, as one on March 18 highlighted the potential for exterior trim panels to detach while driving, and another earlier this month when the NHTSA said its front parking lights were too bright.

Tesla resolved the first with a free assembly replacement, while the headlight issue was fixed with an Over-the-Air software update earlier this week. Owners said there was a noticeable difference in the brightness of the lights now compared to previously.

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Investor's Corner

Tesla investor Calpers opposes Elon Musk’s 2025 performance award

Musk’s 2025 pay plan will be decided at Tesla’s 2025 Annual Shareholder Meeting, which will be held on November 6 in Giga Texas.

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Credit: Tesla China

One of the United States’ largest pension funds, the California Public Employees’ Retirement System (Calpers), has stated that it will be voting against Elon Musk’s 2025 Tesla CEO performance award. 

Musk’s 2025 pay plan will be decided at Tesla’s 2025 Annual Shareholder Meeting, which will be held on November 6 in Giga Texas. Company executives have stated that the upcoming vote will decide Tesla’s fate in the years to come.

Why Calpers opposes Musk’s 2025 performance award

In a statement shared with Bloomberg News, a Calpers spokesperson criticized the scale of Musk’s proposed deal. Calpers currently holds about 5 million Tesla shares, giving its stance meaningful influence among institutional investors.

“The CEO pay package proposed by Tesla is larger than pay packages for CEOs in comparable companies by many orders of magnitude. It would also further concentrate power in a single shareholder,” the spokesperson stated.

This is not the first time Calpers has opposed a major Musk pay deal. The fund previously voted against a $56 billion package proposed for Musk and criticized the CEO’s 2018 performance-based plan, which was perceived as unrealistic due to its ambitious nature at the time. Musk’s 2018 pay plan was later struck down by a Delaware court, though Tesla is currently appealing the decision.

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Musk’s 2025 CEO Performance Award

While Elon Musk’s 2025 performance award will result in him becoming a trillionaire, he would not be able to receive any compensation from Tesla unless aggressive operational and financial targets are met. For Musk to receive his full compensation, for example, he would have to grow Tesla’s market cap from today’s $1.1 trillion to $8.5 trillion, effectively making it the world’s most valuable company by a mile. 

Musk has also maintained that his 2025 performance award is not about compensation. It’s about his controlling stake at Tesla. “If I can just get kicked out in the future by activist shareholder advisory firms who don’t even own Tesla shares themselves, I’m not comfortable with that future,” Musk wrote in a post on X.

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Tesla Cybercab is heading to China’s import expo

The event will take place from November 5–10 at Shanghai’s National Exhibition and Convention Center.

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Credit: Tesla Europe & Middle East/X

Tesla will make its return to the China International Import Expo (CIIE) this November, marking its first appearance at the event since 2022. The U.S. electric vehicle maker confirmed it will showcase its highly anticipated Cybercab, which will make its Asia-Pacific debut during the event. 

The expo will take place from November 5–10 at Shanghai’s National Exhibition and Convention Center.

Tesla Cybercab in China

Tesla announced its participation in the event on its official Weibo account. As per the electric vehicle maker, it would be occupying Booth A3-03 in Hall 2.1 at the National Exhibition and Convention Center. As noted in a CNEV Post report, the Cybercab, the company’s dedicated autonomous two-seater Robotaxi, will be making its Asia-Pacific debut at the CIIE as well. 

The company shared a graphic on Chinese social media which showed an image featuring several Tesla products, such as the Cybercab, Optimus, and Megapack batteries. The graphic also featured a building that read “Master Plan Part IV.”

Tesla’s momentum in China

Tesla’s return comes after skipping the event last year. Interestingly enough, Tesla attended the event from 2018 all the way to 2023. Tesla’s return to the CIIE then aligns with the company’s efforts to attract consumer interest in the world’s most competitive electric vehicle market. 

The Cybercab’s presence in the event could suggest that Tesla might be interested in bringing its Robotaxi to the country. This is quite interesting as China is already home to several autonomous ride-hailing services, though Tesla’s pure vision approach, which focuses on artificial intelligence and cameras, is quite unique. So far, Tesla has only rolled out its autonomous ride-hailing services in Austin, Texas, and the Bay Area, California.

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