Make: Projects

High-Pressure Foam Rocket

Toy or not, this rocket really packs a punch.

High-Pressure Foam Rocket

Calling a rocket that sprints over 100 feet into the air a “toy” might be a bit of a stretch. Toy or not, this rocket really packs a punch. Fly it using the Compressed Air Rocket launcher from MAKE Volume 15 (get the kit at makezine.com/go/launcherkit) or a stomp rocket launcher (makezine.com/go/stomplauncher).

Steps

Step #1: Cut the foam and cinch with a zip tie.

Next
High-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam Rocket
  • Cut a 9" section of foam pipe insulation. Wrap the zip tie 1/2" from one end and cinch it tight so no air will escape. Trim the excess foam above the cinched-off end.

Step #2: Apply duct tape to foam rocket body.

Next
High-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam Rocket
  • Criss-cross 2 pieces of duct tape over the cinched end. Now cover the entire foam section with duct tape spanning the length. Three overlapping pieces of tape should do the trick.

Step #3: Cut and attach foam fins.

Next
High-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam RocketHigh-Pressure Foam Rocket
  • Cut a 4"×1½" rectangle from the foam sheet, then cut it diagonally to make 2 fins. Repeat. Using generous amounts of hot glue, attach 3 of the fins, spaced evenly, onto the foam rocket body tube. If the glue doesn’t stick well to the rough duct tape, wrap 2 strips of clear packing tape over the duct tape around the bottom of the rocket to create a smooth surface for gluing the fins.

Step #4: Use it!

High-Pressure Foam Rocket
  • Pressurize the compressed air launcher for 45psi–65psi, and launch. (For a lower pressure/altitude launch, use a stomp launcher.) When the duct tape finally fails with a spectacular blowout, just apply more duct tape over the blown section and keep flying!

Conclusion

This project first appeared in MAKE Volume 29, page 123.

2 Responses to High-Pressure Foam Rocket

  1. This is very timely. I’ve built the paper air rocket with my son and his friend for their science fair. Next I’m planning to build a modified version to work with foam rockets. I’ve already bought the material, and was planning to build and test it soon.
    It’s good to know that the rocket launcher will have enough “oomph” to push a foam rocket.

    • BTW, I just tested Air Zone foam darts in my launcher. They work fine up to about 30 PSI. At 40 PSI, I blew out the side of the dart!
      Your project has duct tape reinforcing, which I’m sure is why you can get up to those higher pressures. I wonder if using masking tape would add enough strength? It is lighter than duct tape, and with less weight you can fly higher.

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