Ok, well, I saw this thread and knew I had to register on here. A few days ago I started building a homemade rocket launcher. Most of the information 5hifty gave is accurate, but I have a few corrections and additions.
Get some PVC. I have a 4 foot long piece of 3" PVC. One big difference from what 5hifty said is here. You do not, by any means, need high pressure rated pipe. I have cellcore
non-pressure PVC from Lowes. I know this is perfectly safe, one because I know that model rocket engines do not produce anywhere near this amount of pressure, and 2, because I test fired it with an end cap (plumbing type, not the tube cover or whatever mentioned before) barely hand tightened on the back and the pipe didn't explode and, more importantly the end cap didn't come off. If you want to feel safer drill some holes in the cap, but the fewer holes the less backblast there is (it isn't powerful like an RPG, but it is hot). I have 2 9/32 holes (purely coincidental, I didn't drill them for venting) in mine. Also, fitting the tube to the rocket is reversed. This will be nearly impossible. Just trim the fins (try to get a rocket that comes close to fitting because fin clipping will lower it's stability which equals less payload). I trimmed about 1/2-3/4" off the fins of my test shot.
Now you make the cowling, more accurately called a sabot, but for different reasons from mentioned before. Model rockets, when fired normally, are fired in open air which contains the pressure about as well as a sieve. That said, the building of pressure in the tube (if you can even manage to do it) will give you little to no benefit. It would most likely just rip apart the sabot. Also, you could make the sabot from styrofoam, but styrofoam burns, which, while not dangerous, doesn't make your sabots reusable. I made mine from the green oasis foam that florists use (think Wal-Mart craft section). I kinda stumbled upon this stuff. It was readily available in my house and when I fired the rocket I found it to be non-flammable. This stuff is definitely the ticket.
Ignition has to go in here somewhere. I know that drilling a hole in the pipe and running wires from the ignition control box you get with a rocket can be done, but I wanted something better. I made a fully self-contained system. There is a 4 AA battery pack (same as what the Estes launch controller I have uses) mounted to the tube. Then through a cluster of wire you end up with an arming switch and a firing button. The igniter goes in the circuit and away you go. If anybody wants a detailed description of this or a diagram PM me, but if you know anything about electronics this should be easy for you.
Now we get to going boom. This is where ingenuity comes in. I have had endless ideas here but have not had the chance to test them yet (my educator's pack of rocket kits is in the mail...). The big three are here:
1. Explosive (obviously)
2. Incendiary (slower, powerful burn)
3. Kinetic energy (hardest to figure out, but maybe the most promising)
You guys know way more about explosives than I do. Up to this point I have figured mostly on using black powder. I have had trouble figuring out how to make a point detonating fuse (impact). I know I can let the staging charge or recovery charge do the work but PD fusing is way cooler. I have thought about using a pin (like the plunger mentioned before) to strike a percussion cap. This was the first mention I have heard of using pure pressure. I want more opinions. Will it work? If not, what is the best way? Help in this area would be most appreciated. Also, until a little while ago I had not considered using higher (not meaning high explosives in the technical way, just higher velocity than black powder) explosives. I would love ideas here (I know nothing about this but an trying to learn).
Incendiary is fun. I considered thermite but I'm pretty sure that it would be too hard to ignite reliably (a pile of thermite beside the smoldering hulk of a rocket is bad). I thought phosphorus, metal powders (that would be more of a bang than a burn though, right?), and gasoline/napalm (easiest). PD fusing is a concern here too.
Finally is kinetic energy. I would need more powerful rockets than what I have now (yay, more cash per shot) to accommodate larger engines. If I used a short burn/high energy motor I think I would get what I want. G size motors can propel un-payloaded rockets to well over 800 mi/hr. I figure the impact of a 1-2 pound semi-pointed projectile at anywhere near, say, 500 mi/hr would be able to wreak some serious havoc. I'm thinking going though a cinder block wall with a few. While sounding the simplest this idea will probably be the hardest to actually implement.
A few closing thoughts. For one, this ended up being a lot longer than I thought. Also, if you do this, make sure to PAYLOAD TEST YOUR ROCKET WITH AN INERT SUBSTANCE before throwing back powder/flash powder/napalm in there. Chances are that your payload, on your first try, will make your rocket unstable, which will most likely land it a few feet away. You will need to tune the location and size of your payload (filling the tube will almost definitely not work, depending upon the rocket).
Also, in terms of igniting things, the booster stage motors (designated with a 0 for their final number, i.e. C6-0) will be the best. They spray flame and burning chunks of black powder into the body of the rocket. This is a feasible way to ignite things, but once again, I want PD fusing.
The cost, all told, for the launcher, comes to about $30. Cheap, eh? Not quite. The real cost is the cost per shot. We aren't shooting potatoes here. I figure that with my 12 pack of rocket kits, plus the cost of motors, I will run $4-4.50 per INERT shot. Any payload like black powder, flash powder, gasoline, or phosphorus is extra. It looks expensive, and it is, but when you consider that the US military's new AT (the AT-4, I believe) rocket consists of a disposable plastic tube, with a shape charge glued to a quick burn rocket and some fins, it eases the pain. If you got your hands on some C4, or other high explosive, and some copper sheet, you could, in a very literal (and scary) way, have an RPG.
Now the results from the test shot and plans for the future. The test shot was an Estes Alpha III rocket with a C6-5 (I think it was 5, but the last number is negligible). I shot it at what I guess to be a 30 degree angle. It flew quite literally out of sight and my friend and I were never able to find it. My best guess says approx. 1/4-1/3 of a mile. This would easily be accurate out to 250 yards if you figure out how to aim it (it flies straight on the x-axis, but getting elevation right would be the trick). The future holds 12 rocket kits on the way and no less than one container of gunpowder. I am also going to try match heads and napalm without a doubt. The kinetic energy idea will have to wait for more money, time, and knowledge. I have pictures below and when I get my rockets and fire them I will put a video on YouTube and link it from here.
The whole thing
Arming switch and on light
Firing button
Alligator clips for attaching to the ignitor
