Crazy, yes, but so crazy…it…just….might….wooork…
If you want to build something quick and inexpensively,
sometimes using what already exists can be a big help (and sometimes it
isn’t). In considering ways to build a
small manned launcher in the shortest amount of time, the application of this
principle would be to find an existing small launcher and an existing small
space craft. In this case, the existing small launcher
would be the Falcon 1E. The existing
small space craft would be Spaceshipone, or more specifically, the front end of
Spaceshipone, i.e. the pressure vessel part that carries the pilot, passenger(s),
controls, instruments, air, RCS supply, et al, minus the wings, empennage, N2O
tank and motor case. This is handy, since SS1 has already demonstrated operational-capability in space with real-live people.
Turns out, this Front end part of Spaceshipone is small
enough to fit within the payload fairing of the Falcon 1E:
So, what about the use of a stripped-down Spaceshipone? Ok, from here on out, we get into wild, highly-speculative, unsubstantiated guesses about component masses. I expect this to be fodder for endless postings, but here I give you my guesses at component masses.
The empty (or dry) mass of Spaceshipone (no N2O, no fuel in the motor case) is stated to be about 2646 lbm. So we need to come up with estimates for the N2O tank mass, motor case mass, nozzle, N2O valve, landing gear, wings/empennage, and intertank skin-and-fairing, then deduct these from the empty mass. Assuming a roughly spherical tank about 60 inches in dia., operating at around 750 psi, and making guesses for material strength and density and a tank safety factor, I come up with a N2O tank mass of about 880 lbm (right? wrong? close? I don't know). Doing the same thing for the motor case, I get about 465 lbm. I guessed the nozzle mass to be about 40 lbm, the valve to be about 70 lbm, wings/empennage about 300 lbm, landing gear about 100 lbm, and the intertank skin/aft-fairing to be about 80 lbm. Deducting these from the empty mass, this yields an operational capsule mass of about 707 lbm. And by operational capsule mass, what I mean is that it contains radios, nav aides, ELT, instruments, batteries, controls and linkages, Enviro. cntrl system (ECS), basically everything that's currently in the SS1 pressure vessel.
Ok, but we’ve got other stuff to add to the capsule to make
it space worthy. In this estimate, I’ve
assumed that there would be two occupants: a pilot and a passenger. Here’s my shopping list:
Upgraded RCS: 200 lbm
Upgraded ECS: 50 lbm
Parachute system: 150 lbm
Re-entry Heat Shield: 200 lbm
De-orbit motor: 100 lbm
Operational Capsule: 707 lbm
Misc: 100 lbm
However, something to keep in mind, even if the resultant mass is still heavier than
the Falcon 1E capability, it still might be interesting as a suborbital ride,
though perhaps a bit pricey.