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Chapter 5 - Ground Effects
Chapter 5 - Ground Effects
Making 101
Fireworks Making 101
Skylighter, Inc.
PO Box 480
Round Hill, VA 20142-0480 USA
© Copyright 2012 by
Skylighter, Inc.
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Fireworks Making 101
Introduction
This book is designed to give you an overview of how the most popular types of
fireworks are made: stars, aerial shells, and rockets.
This little book is by no means exhaustive. But it will give you a fairly complete
presentation of most of the current types of stars, shells and rockets commonly
used in fireworks today, and a brief overview of how each type is made.
The sections are designed in “building-block” fashion. First you learn about stars
and other devices used inside aerial shells. Next you’ll see a section on different
types of and construction alternatives for aerial shells. And finally, the chapter on
rockets shows you rocket engines and how shells can be used as rocket
“headings.”
There are many, many kinds of fireworks you can make, other than the ones
shown here. But these are the ones most requested by our customers at
Skylighter. So, this is a good starting point for learning to make aerial shells and
rockets and just what goes into them.
All of the chapters in this book were written by Ned Gorski, and we are indebted
to him for his thoroughness and clarity in their presentation.
We welcome your input and suggestions for changes and corrections. Just
address them to info@Skylighter.com.
Just click here to sign up for detailed plans on making every kind of
fireworks you can imagine. The plans and projects are free. There’s no
catch, no credit card required.
When you sign up, you’ll receive an exciting new fireworks-making project
every 3-5 days by email. Each one gives you a detailed, step-by-step
tutorial that shows you exactly how to make each type of firework.
Tutorials are all instantly downloadable and contain color photos, detailed
diagrams, and even videos to show you exactly what to do.
There is no charge for the tutorials, and you can unsubscribe to them
anytime you want. You are not obligated to buy anything, although we do
hope you will consider Skylighter when you need fireworks chemicals,
fuse, tubes, tools, and other supplies.
Skylighter.com - 3 -
Fireworks Making 101
Thank you.
Harry Gilliam
Chief Cook & Bottlewasher
Skylighter, Inc.
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Fireworks Making 101
Contents
Introduction.............................................................................. 3
Contents ................................................................................... 5
Stars & Shell Inserts................................................................ 7
Introduction ................................................................................................ 7
Fireworks Stars........................................................................................ 10
Star Effects .............................................................................................. 11
Star Manufacturing Processes................................................................. 12
Cut Stars.................................................................................................. 12
Pumped Stars .......................................................................................... 15
Rolled Stars ............................................................................................. 18
Garnitures Wrapped in Paper .................................................................. 19
Conclusion ............................................................................................... 23
Aerial Shells ........................................................................... 25
Ways of Launching Shells........................................................................ 27
Shells Launched on Rockets ................................................................... 27
Shells Fired from Mortars......................................................................... 28
Parts of a Shell ........................................................................................ 29
Size Does Matter ..................................................................................... 30
Paper or Plastic? ..................................................................................... 30
Balls or Cans? ......................................................................................... 31
Welcome to Aerial Shells. Will that Be a Single, Double, or Triple?......... 32
Garnitures ................................................................................................ 33
An Overall Shell Description .................................................................... 33
Fireworks Rockets................................................................. 36
There are Rockets and Then There are Rockets..................................... 37
Fireworks Rockets in Depth ..................................................................... 40
Anatomy of a Fireworks Rocket ............................................................... 42
Size Does Matter ..................................................................................... 43
Traditional Fireworks Rocket Size Nomenclature .................................... 44
Rocket Motor Sizes and Designations ..................................................... 45
Types of Fuel Used in Fireworks Rockets................................................ 46
Overview of Fireworks Rocket Construction Methods ............................. 48
Nozzled versus Nozzleless Motors .......................................................... 49
Methods of Consolidating Rocket Fuel .................................................... 50
Means of Stabilizing a Rocket.................................................................. 51
Rocket Heading Types............................................................................. 52
Summary of A Rocket’s Nomenclature .................................................... 52
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Fireworks Making 101
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Chapter 1 – Stars & Shell Inserts
Introduction
“Garnitures.”
Kind of an old-fashioned word, not heard very often in conversation. But, as used
to describe the class of fireworks components we are about to look at, I’ll be
darned if I can find a better word.
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Chapter 1 – Stars & Shell Inserts
And, from the dictionary, the root of the word “garniture” lies in the term “garnish,”
which is defined as “to furnish with beautifying details.”
To furnish with beautifying details. Doesn’t that sound lovely? That’s exactly what
we are asking of our various types of garnitures.
There are basically two “sub-assemblies” of a fireworks shell. The first assembly
includes the shell leader-fuse, the lift powder, the time fuse, the shell casing, and
the burst powder. That whole integrated construct, though, serves one purpose–
that of getting the second assembly, the garnitures, up into the air and ignited.
Without the garnitures, the shell wouldn’t really serve any purpose.
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Chapter 1 – Stars & Shell Inserts
Large stars attached to the outside of a shell will create a rising tail as the shell
ascends skyward. These large rising tails can also be created for rockets by
attaching a large comet to the exterior of the rocket motor or heading, to be
ignited when the rocket launches.
Small star shells or reports can be attached to a shell to create “ascending small
flowers” or “ascending thunder.” Or attaching a whistle can augment a shell’s
ascent.
Although stars are typically the first components that might come to mind as the
contents of a shell, when you stop and think about it there are actually many
different varieties of shell inserts.
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Chapter 1 – Stars & Shell Inserts
Taken together, all of these devices comprise the largest and most diverse class
of components in fireworks making. A very wide range of construction techniques
and fireworks effects is included in this category.
The broad category of garnitures can be subdivided into two parts–stars and
inserts. The effects, construction, and manufacturing methods of these two
categories are quite different. Generally, fireworks stars are increments of
pyrotechnic composition bound into pellets. Inserts are bound in paper tubes,
paper sheets, or other types of casings. Inserts may themselves contain stars.
Fireworks Stars
When we picture the traditional “flower” display of an aerial shell, the individual
points of light and trails of sparks are created by “stars,”–pyrotechnic composition
which has been bound into solid pellets.
Simple firework stars are like small charcoal briquettes, with the composition
bound together using a binder such as dextrin, some other starch, or a gum.
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Chapter 1 – Stars & Shell Inserts
Star Effects
Virtually an endless array of visual and audible effects can be produced by
fireworks stars. Most of these effects result from the different compositions
used to make the stars. You’ll hear star formulas described as “charcoal
streamer star” or “color star” or “silver-spark streamer” or “strobe star,” etc. These
different effects are created from the different chemicals in the composition
formulas.
Other star effects are the result of different processes used to make the stars:
pumped stars, cut stars, box stars, rolled stars, go-getter stars, etc. Many
different effects are dependent on the method that is used to make the stars.
The star effects listed below are created simply from different consolidated
compositions, with no tubes or wrappings on them. (Composition-filled tube
effects will be described in a minute):
Firefly stars
Crackling stars
Strobe stars
Those are just some of the different effects which arise from simply varying the
type of composition that stars are made from, or the star size, and/or the process
used to manufacture the stars.
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Chapter 1 – Stars & Shell Inserts
Cutting stars
Pumping stars
Rolling stars
These three methods produce stars with shapes unique to each method:
Cut Stars
Cut stars are quick and easy to make, and have traditionally been the stars of
choice in Italian-American style cylinder shells. No special machines or
equipment are necessary to make cut stars. This makes star-cutting relatively
inexpensive. Cut stars can be stacked carefully in ball shells, too:
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Chapter 1 – Stars & Shell Inserts
Cut stars have sharp corners and edges which make for good star ignition. They
“lock together” when filled into cylindrical shell casings, enhancing the integrity
and strength of the resulting shell.
Since cut star composition has to be pretty wet to make it suitable for cutting,
when the comp is bound with water-dextrin, the resulting stars can take longer to
dry than stars made with other methods.
Cut stars also have the disadvantage of not having completely consistent sizes,
due to the manufacturing method. So, some of them will burn out before others
after the shell bursts. They also do not have a very aerodynamic shape,
compared to a round/spherical star; so they do not produce as symmetrical a
pattern in the sky as round stars do. Cut stars produce only one single color or
effect.
Cut stars do have the advantage of being able to be made in any size batch,
from a small 2-ounce batch, up through a 30-pound one. And they can be made
and primed all in one single step, rather than requiring multiple layers to be built
up, often necessary when rolling stars.
For small batches of cut stars, a “pancake” can be made out of the dampened
star composition. This flat pancake is then dusted with star prime, and sliced with
a thin, straight-edged knife.
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Chapter 1 – Stars & Shell Inserts
For larger batches of cut stars, a “loaf-box” can be made and lined with waxed
paper. Damp star composition is rammed into the box to form a loaf of star comp,
and the loaf is ejected from the box-frame. Slices of the loaf are then sliced off of
it, and these slices are then cut into stars in the same way the pancake above
was.
One more cut-star method has recently become popular for making relatively
small batches of parlon-acetone bound stars–“screen-slicing.”
When the patty is pushed through the screen, stars are sliced quickly, and they
end up consistently sized, too. Star priming can be incorporated into this one-
step slicing method.
These parlon-acetone bound stars make wonderful colors and effects. Best of all,
they dry very quickly, so you can use them in fireworks devices after only a few
hours.
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Chapter 1 – Stars & Shell Inserts
Pumped Stars
Pumped stars are made by packing slightly dampened star composition into a
hollow cylinder, either a single-star pump, or a gang pump called a star plate.
The star composition is then consolidated with either hand pressure, hand
ramming with a mallet, or with the use of a hydraulic or pneumatic press:
Pumped stars stack very nicely inside cylindrical shell casings, resulting in strong
shell integrity. This is advantageous when large, multi-break cylinder shells are
being made.
The use of single star pumps or star plates makes this method of star
manufacture a little more expensive than star cutting.
Looking at the photo above brings up a question: What is the difference between
a comet and a star? Many fireworkers would describe the large diameter pump
above as a comet pump, and the plate as a star plate. The large “puck” could be
described as a comet, whereas the smaller pellets could be described as stars.
And any projectiles, fired in multiples out of shells or mines, would be referred to
as stars, once again regardless of their size.
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Chapter 1 – Stars & Shell Inserts
So, it is the use that pumped projectiles are put to–not their size–which
technically determines whether they are comets or stars.
But, in practice large projectiles, as singles or groups fired from a shell or mine,
are often referred to as comets. And small projectiles, even if they are fired one
at a time, as is done from roman candles, are often called stars.
The bottom line is that it’s not always cut-and-dried as to whether a projectile is
called a star or a comet. And the distinction is not really important.
Although the pumped stars shown above are pellets made with simple tooling
and a single-effect composition, more complex stars and comets can also be
made.
Small contrasting-effect stars, such as color stars, can be mixed in with the larger
comet composition, such as a charcoal-streamer or glitter formula, prior to
pressing the comet. When the comet burns, the color stars stream behind it,
mixed in and contrasting with the charcoal or glitter tail trailing behind the
projectile. This is called a matrix star or comet.
Cavity-Star Pumps
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Chapter 1 – Stars & Shell Inserts
Crossettes (splitting stars and comets) are made using only one star
composition such as a charcoal-streamer or glitter composition. What makes
crossettes unique is that the stars begin flying through the air as a standard star
would. But then the individual stars split into fragments which fly off in opposite
directions.
These stars are made using a crossette pump. These pumps can either
resemble the cavity-star pumps shown above, except with smaller diameter
cavity-forming projections on their pistons, or they can have “cross-shaped”
projections as shown below.
After a crossette has been pumped and dried, the cavity in it is filled with either a
loose powdered explosive, or with a small “firecracker hole shot.” Then the star is
pasted with paper except for the solid end. The comet burns from that solid end
until the explosive is reached. At that point the projectile splits into fragments,
which fly away from each other.
This sudden splitting of all the stars in a shell burst is very surprising and
impressive, especially if the stars have been carefully crafted so that they all split
simultaneously.
So, you can see that different star pumps, compositions, and construction
techniques can create different effects in the sky as the pumped stars and
comets fly through the air.
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Chapter 1 – Stars & Shell Inserts
Rolled Stars
Spherical stars, often called round stars, are made using a star-roller. These
stars have an aerodynamic shape and fly through the air in straight trajectories.
The stars can be sized during the rolling process in order to create batches of
stars which have very uniform, consistent sizes.
Consistent sizing of rolled stars is highly valued because it results in stars which
either change color and/or burn out all at the same time.
One of the really significant advantages of rolled stars is that they can be made
with one color composition rolled first, followed by a different color rolled on top
of that first one. This produces color changing stars.
Different colors or effects are often rolled up in thin layers and allowed to dry
between those layers. So the overall star rolling process can be a lengthy one.
But, large batches of stars can be made using the rolling method.
Advanced fireworkers can produce stars which change colors multiple times, or
start with a color, go dark for a short time, and then flash on with color again,
seemingly out of nowhere.
Precisely rolled stars are the hallmark of the highly artistic Japanese ball shells.
Star rolling begins with cores such as a small cut stars, lead shot, small seeds, or
even little pieces of pasta. An advanced technique for starting star-rolling
involves “spritzing” dry, powdered star composition with a water-filled spray
bottle, to create cores on which to continue rolling the stars.
Star composition is layered onto these cores using a star roller. The simplest star
roller can be a round or flat-bottomed plastic or metal bowl. The bowl is swirled
round and round by hand as the star cores are dampened with sprayed-on water,
and more dry star composition is slowly added to “grow” the stars as they roll.
Usually, though, a mechanized star roller of some sort is used. A round container
of some sort is rotated by a motor as stars are rolled. Plastic or metal drums,
large or small bowls, or even rubber tires, are used in various versions of the star
roller.
Using a star rolling machine usually makes this method of star manufacture more
expensive than cutting or pumping stars.
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Chapter 1 – Stars & Shell Inserts
So, in summary, simple fireworks stars can be made from basic compositions
bound in pellets with binders. Many different effects can be achieved by varying
the star formulas or the process by which the stars are made.
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Chapter 1 – Stars & Shell Inserts
Small insert shells can be used inside larger shells, to create a “shell-of-shells.”
These inserts can be filled with any of the various garnitures we are discussing,
or they can be filled with a report composition to create simple flashes of light
and sound when they burst.
Graceful falling leaves stars are made by troweling, like frosting a cake, soft
composition between layers of paper. Once the composition is dry, the sheets of
paper-bound composition are cut to size, and one end of the falling-leaves is
primed to ensure good ignition. These stars softly break out of a bursting shell,
and gracefully drift toward the ground dropping like colored falling leaves.
Box stars, sometimes called pillbox stars, are made by pressing some
dampened star composition into thin-walled paper tubes. The tubes are made by
rolling about 4 turns of kraft paper on a ½-inch diameter rod, and securing the
edge of the tube with glue. The star tubes are cut ¾-inch long, and a piece of
blackmatch is inserted into the tube with the match sticking out of both ends of
the tube.
These tubes are then filled with dampened star compositions which are
especially suited to these stars. Because of the embedded blackmatch, which
takes and holds fire very well, these stars ignite easily and are not blown blind by
a hard shell burst. The compositions used to make them burn a long time, and
very brilliantly, resulting in a long duration, dramatic display of drooping brilliant-
color stars.
Hummers sound like their name implies; these tube inserts create a whirring
sound which can be accompanied by a spiraling spray of sparks. A fuel
composition is rammed between two clay plugs in a strong-walled cardboard
tube. Tangentially-drilled vent holes cause the inserts to spin and whir as the fuel
burns.
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Chapter 1 – Stars & Shell Inserts
Farfalle inserts (plural for the Italian farfalla), called butterflies in English, are
constructed identically to hummers, except the two holes are drilled at the same
time, on opposite sides of the tube, straight through the center of the tube. This
results in a butterfly-shaped spark spray which causes the inserts to wobble and
spin erratically as they fly through the air.
Serpents are another variation on the theme of clay plugs and fuel rammed in
cardboard tubes. Instead of vent holes in the tube, though, a serpent has one
vent hole through one of the clay plugs, as would a small rocket motor.
An ignition fuse is installed in that hole to ignite the fuel when the insert is ejected
from a fireworks device. The resulting spray of gasses and sparks causes the
serpent to fly in a serpentine manner through the sky.
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Chapter 1 – Stars & Shell Inserts
Whistles can be used as pyrotechnic inserts. The shrill whistling sound which
results from the whistle fuel can be augmented by bright sparks if metal particles
are included in the fuel. Whistle fuel is never hand-rammed, only pressed with an
arbor press or hydraulic press.
Another creative effect can be achieved with scatter stars. These inserts burst
out of the shell “blind,” with no immediate visible effect at all. Then, suddenly, out
of nowhere, dozens of stars appear, shooting every which way in the sky.
Go getters create a similar effect when they fly out of a shell burst, except their
vibrant colors are visible right away. Then, suddenly, the self-propelled go getters
zip in every possible direction.
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Chapter 1 – Stars & Shell Inserts
The method for making go getters is unique in that a liquid form of star
composition is squirted out of a plastic squirt bottle into small paper tubes. A
small piece of doubled blackmatch is inserted into each go getter, and the inserts
are allowed to dry. The bottom end, which is not designed to ignite, is dipped in
Elmer’s glue to seal it.
Conclusion
You can see that this broad classification, garnitures, includes quite a variety of
effects, uses, and manufacturing methods. From the simplest compositions and
techniques, such as charcoal-tailed cut stars, to the most complex applications
and techniques, garnitures serve a wide variety of purposes in fireworks.
Simply experimenting with and learning about these ways to “furnish our
fireworks devices with beautifying details” can keep us challenged for many
years in the art that is pyrotechnics.
--Ned Gorski
Just click here to sign up for detailed plans on making all kinds of
fireworks stars. The plans and projects are free. There’s no catch, no
credit card required.
When you sign up, you’ll receive an exciting new fireworks-making project
every 3-5 days by email. Each one gives you a detailed, step-by-step
tutorial that shows you exactly how to make each type of firework.
Tutorials are all instantly downloadable and contain color photos, detailed
diagrams, and even videos to show you exactly what to do.
There is no charge for the tutorials, and you can unsubscribe to them
anytime you want. You are not obligated to buy anything, although we do
hope you will consider Skylighter when you need fireworks chemicals,
fuse, tubes, tools, and other supplies.
Skylighter.com - 23 -
Chapter 1 – Stars & Shell Inserts
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Chapter 2 – Aerial Shells
2
Aerial Shells
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Chapter 2 – Aerial Shells
These Shells!
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Chapter 2 – Aerial Shells
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Chapter 2 – Aerial Shells
“Reloadable” means that once the shell is fired, another shell can be loaded and
fired from the same mortar. The long ignition fuse leads to black-powder lift
charge which is attached to the shell in a lift bag. The shell is loaded in the
mortar, which is safely secured, and the fuse is ignited at the top of the mortar.
Some consumer fireworks shells are not reloadable. They come as “single-shot”
devices, with an ignition fuse installed in the side of the mortar at its base. The
black powder lift charge has been dumped loose in the bottom of the mortar, and
the shell has been dropped into the mortar on top of the lift powder. Those
components are held in place at the bottom of the mortar by pieces of cardboard
pressed down on top of the shell.
With these single-shot units, the mortar is secured, the fuse ignited, and one
shell is fired from the mortar, which is then thrown away.
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Chapter 2 – Aerial Shells
Parts of a Shell
Here’s the sequence of events that happens when a mortar-fired shell does its
thing:
The lift charge fires the shell into the air from its mortar and
The flame from lift powder ignites the shell’s time fuse.
Inside the shell, the time fuse ignites the shell’s burst powder.
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Chapter 2 – Aerial Shells
Some consumer fireworks shells come with mortars as small as 1-inch. Other
record-setting shells have been fired from 36-inch, and even 48-inch mortars.
Paper or Plastic?
Almost all shells are made from one of two types of material: paper or plastic.
Most budding pyros start out making aerial shells with plastic casings, and the
majority eventually switch to using paper for their shells.
Standard size, plastic shell casings have the advantage of being quick, easy, and
simple to assemble. But, typically, they do not produce ideal burst symmetry, and
they spread plastic debris around the shoot site.
Paper casings are more traditional, produce better shell bursts, and leave only
biodegradable paper debris behind. But, the techniques for making paper shells
are more involved, take more time, and require more practice to master.
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Chapter 2 – Aerial Shells
Balls or Cans?
Shells can be further classified by shape--spherical or cylindrical. The former are
referred to as ball shells, and the latter as cylinder shells.
The casings shown above are used to produce ball shells, like the ones shown at
the beginning of this article. Ball shells have their roots in the Orient, starting in
Japan, then migrating to China and elsewhere.
Machine-made paper and plastic casings are used to make simple cylinder (also
called “can” or “canister”) shells.
More traditional, hand-production techniques are used to produce the largest and
most complex of cylinder shells. These techniques originated in Italy and have
flourished in Malta, and incorporate paper, paste, and string.
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Chapter 2 – Aerial Shells
In a peanut shell, the time fuses in all the assembled shells (breaks) typically
take fire at once, from the lift charge’s flame.
In a “multi-break” cylinder shell, two or more cylinder shells are combined into
one assembly. The fuse for the first break takes fire from the quickmatch leader,
and each succeeding break taking its fire from the explosion of the previous
break.
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Chapter 2 – Aerial Shells
The above illustration is taken from the two-part series on cylindrical shell
construction techniques by “A. Fulcanelli” in Pyrotechnicas IX and XI. This series
is considered to be the “bible” in making Italian style, cylindrical multi-break
shells.
Garnitures
What the heck are garnitures?
Garnitures are what an aerial fireworks shell is all about. They are the visual
and/or audible effects being carried into the air to be displayed at the perfect
moment.
How it’s getting into the air: rocket heading or mortar fired.
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Chapter 2 – Aerial Shells
“Well, I’m holding a 12-inch, mortar-fired aerial shell. It’s a paper ball shell, with a
rising tail, designed to produce a large silver palm-tree effect, with two red
coconuts.” Which would look like this.
Now there is a whole lot more to making shells than what’s contained in this brief
article. In fact, the variations in shell-making are probably infinite. But these are
the basics, the nomenclature, and the fundamental alternatives.
--Ned Gorski
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Chapter 2 – Aerial Shells
Just click here to sign up for detailed plans on making all kinds of aerial
shells and other fireworks. The plans and projects are free. There’s no
catch, no credit card required.
When you sign up, you’ll receive an exciting new fireworks-making project
every 3-5 days by email. Each one gives you a detailed, step-by-step
tutorial that shows you exactly how to make each type of firework.
Tutorials are all instantly downloadable and contain color photos, detailed
diagrams, and even videos to show you exactly what to do.
There is no charge for the tutorials, and you can unsubscribe to them
anytime you want. You are not obligated to buy anything, although we do
hope you will consider Skylighter when you need fireworks chemicals,
fuse, tubes, tools, and other supplies.
Start learning to make your own fireworks shells right now, by clicking
here.
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Chapter 3 – Fireworks Rockets
3
Fireworks Rockets
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Chapter 3 – Fireworks Rockets
But leaving those aside, there is a wide variety of rocketry that folks can and do
explore for purely recreational purposes. Such rockets include model rockets,
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Chapter 3 – Fireworks Rockets
Model Rocket
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Chapter 3 – Fireworks Rockets
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Chapter 3 – Fireworks Rockets
From Wikipedia:
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Chapter 3 – Fireworks Rockets
Additionally, the rocket motor is often fitted with a “heading,” which creates a
traditional fireworks display—for example, a loud report, a shell burst of stars, or
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Chapter 3 – Fireworks Rockets
a display of other types of fireworks inserts—at the end of the rocket’s powered
flight.
The diagram above shows the elements of a typical fireworks rocket. The top of
the rocket is on the right, and the bottom of the rocket is on the left.
The rocket motor consists of the paper tube (case), which has a clay nozzle
built into the bottom of it to direct the rocket exhaust. It is packed with fuel to
provide thrust (“thrust fuel”) and a delay (“delay fuel”) after the thrust fuel is
exhausted. The top of the tube is partially closed by a clay bulkhead which has a
“passfire” hole built into it.
The second component is the rocket stick, which is attached to the side of the
rocket motor and extends to the left. The rocket stick provides stabilization to the
rocket at lift-off and in flight.
Finally, attached to the top of the rocket motor is the heading containing stars
and burst. The heading is responsible for the fireworks display seen in the sky
as the rocket reaches the top of its climb.
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Chapter 3 – Fireworks Rockets
Although it might not seem so at first glance, there is a very big difference
between, say, a 3/8-inch ID “magnum” bottle rocket and a ½-inch ID rocket
motor. Calculating the cross-sectional areas of the two sizes of motor-tubes, and
also the total volumes of the tubes, the fact is that a ½-inch motor is between 2
and 2.5 times as large (in terms of volume) as a 3/8-inch ID motor. This is easy
to see in the next photo.
The large skyrockets you can buy at your local fireworks store typically have ½-
inch ID motors. A ½-inch black-powder motor can carry a heading of between 1
and 2 ounces into the air. That’s the same weight as a spherical or cylindrical,
consumer-sized, aerial fireworks shell.
The handmade rockets shown above are very nice, real rockets. Yet they are
small enough to be suitable for flight in almost any area where rockets from the
fireworks store could safely be displayed.
Half-inch, black-powder rockets are a great place to start, and I personally enjoy
the heck out of making them to this day. They are small enough that they can be
made quickly and don’t use huge amounts of materials. But they are large
enough to really be impressive. They provide that black-powder-rocket “whoosh”
as they launch, and they’re able to carry a nice payload of stars or other
garnitures into the air.
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Chapter 3 – Fireworks Rockets
It’s a relatively long and complicated story which Barry Bush relates in detail in
the fireworks chapter of Pyrotechnics by Alexander Hardt. Over the past several
hundred years, an evolution occurred in the nomenclature used to describe
rockets. That resulted in ½-inch ID rockets being referred to as “4-ounce” rockets
in the US. Similar terminology is used to describe other sizes of rockets (see
table below).
These designations have nothing to do with the actual weight of the rocket
motors, nor their payload carrying capacity, nor their thrust. They are simply
arbitrary, meaningless designations which can be difficult to remember at times,
and which really only pertain to black-powder rockets. As a result, many
rocketeers simply refer to their rockets by the motor’s ID nowadays.
But old habits and traditions are not quick to die, so here is a table of the
traditional black-powder rocket designations used in the US, and the
corresponding motor ID’s and common tube-lengths (may vary slightly from one
maker to another):
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Chapter 3 – Fireworks Rockets
You can see from the table that the length of the tube is approximately 10 times
the tube’s ID. This can vary a little from one maker to another, though.
On the small end, there are ¼-inch ID and 3/8-inch ID “bottle rocket” tubes and
tooling available as well, and we could call these “1-ounce” and “2-ounce”
motors.
On the large end, some rocketeers, with the necessary space to fly them, make
larger fireworks rockets too, sometimes referring to them as “30-pound” or “60-
pound” motors.
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Chapter 3 – Fireworks Rockets
But perhaps the biggest advancement in fireworks rocketry in the past 50 years
has been the development of different fuels, other than the traditional black-
powder fuel.
“Whistle fuel” is used in whistling rockets, and also in conjunction with other types
of fuel as a powerful booster.
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Chapter 3 – Fireworks Rockets
“Strobe” fuel, used with a whistle-fuel booster, produces one of the most striking
visual, and especially audible, effects of any fireworks rocket. A brightly flashing
tail is accompanied by loud “popping.” It almost sounds like an incoming
helicopter.
Rockets with brilliantly colored tails can be made by using color-producing fuels.
Such rockets often use whistle fuel as a booster. Powerful “hybrid fuels” can be
made by mixing granulated black-powder fuel with granulated whistle fuel, and
pressing that fuel mixture in motor tubes.
Other fuels such as zinc-sulfur fuel, and “sugar” or “candy” fuel—to mention only
a couple—have also been developed. So you can see that starting with just the
rocket motor, there is plenty of room for creativity and experimentation with
fireworks rockets.
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Chapter 3 – Fireworks Rockets
In a traditionally made black-powder rocket motor the hard clay nozzle is formed
by ramming powdered clay into the bottom of the tube. This is done using the
tooling, a mallet and a sturdy ramming post for a base. The spindle forms the
central hole in the nozzle.
The fuel in a fireworks rocket must also be compacted into a solid mass (called a
“grain”) in order to ensure that burning of the fuel proceeds in a controlled
fashion. This process is called “consolidation.” In the case of our black-powder
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Chapter 3 – Fireworks Rockets
rocket, fuel consolidation is also achieved using the tooling, mallet and ramming
post. The fuel, made of potassium nitrate, charcoal, and sulfur, is rammed into
the paper tube above the nozzle in a series of small “increments” to ensure
consistency.
A clay bulkhead with a passfire hole is rammed on top of the finished fuel grain,
and finally, a heading is added at the top end of the rocket.
An “end-burner” motor would be made in a very similar fashion, but with a very
short spindle which only penetrates through the rammed nozzle. The fuel grain of
an end-burner black-powder motor has no core going up into the center of its fuel
grain.
The whistle and strobe motors shown in the previous sections do not use clay
nozzles either. They typically do have a core formed up into their fuel grain.
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Chapter 3 – Fireworks Rockets
But more sensitive fuels like whistle or strobe composition should not be
subjected to the shock associated with ramming. Also it is sometimes desirable
to achieve higher densities of compaction. In these cases, mechanical or
hydraulic presses are used to press increments of the fuel into the paper tubes.
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Chapter 3 – Fireworks Rockets
Fin stabilization, as shown in the photos above of the various rocket with
fins on the rocket bodies.
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Chapter 3 – Fireworks Rockets
A simple star, or small cluster of them, can be taped to the top of the rocket
motor, and they will signify when the rocket’s powered flight is completed.
A “bag shell” heading can be constructed of a few turns of kraft paper on the
motor’s end, filled with black-powder burst charge and a handful of stars.
Or, any complex aerial ball shell or cylinder shell imaginable can be installed on
the rocket motor to create a complex aerial fireworks display at the top of the
rocket’s flight.
The type of fuel or fuels used in the rocket motor’s construction, along with a
description of the desired tail effect.
The type of fuel consolidation used when making the motor: hand rammed or
pressed.
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Chapter 3 – Fireworks Rockets
Whether the fuel grain has a core in it or not: cored (or core-burner) or end-
burner.
--Ned Gorski
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