I will take you through step by step how i have gone about making them and a little video at the end of 2 4" test shells. There were 3x 3" and 2x4" but only caught the 4s on camera.
I weigh out the chems as per the ratio by veliene, i grind the safe chems together in my coffe grinder and the oxidisers seperatly. I then screen them together by passing the mix through a seive around 10 times and mixing with a spoon in between each " turn". Once my mix is ready i either roll them onto little lead shot or i make star cores ot of the mix first let them dry then roll onto them. Once the star mix is rolled and i have nice spherical balls ( or as close as i can get) then i roll my prime on, my prime is mill dust with around 5% silicon and roll around 1mm-2mm onto the stars.
I allow them to dry for as many days as it takes in a warm dry place until i can only break them by crushing them with a set of pliers.
No for the things ive tested and changed,
1, I have added more and less silicon to the prime
2, i have rolled 1/2mm layers at a time and let dry before adding the next layer onto the star.
3, i have tried using tigertail mix as an inner prime and bp as an outer prime.
4, I have tried letting the star dry on their own before rolling on a prime.
5, I have tried adding dark ali to the prime.
There may be other things ive tried but cannot remember at present. Its beginning to really piss me of now as i thought i had it nailed until i did the test shells. Strangley the smaller stars in a rocket i made seemed to light perfectly, they were around 4mm with a 1 mm layer of bp/silicon. I will add the video of the rocket aswell. The bang is a 6 gram flash salute i added but it went of abit delayed it was supposed to be the main burst.
Any suggestions on what i could be doing wrong here as i think ive had a go at it from all angles. The only things i have not tried are as follows,
1, try using acetone to activate the red gun as the binder instead of water/alchol mix.
2, cutting the stars instead of rolling.
The strange thing is the prime allways ignites without fail its just the prime fails to light the star. I may be barking up the wrong tree here but i have been thinking about a problem that may arise when rolling. From what ive noticed some particles in the mix seem to stick better than others, could this result in the original well mixed composition being " un-mixed" in the process of rolling? Probably wrong but ime scraping the barrel now.
The videos are here and here excuse the little bit of giggling i get abit to excited when experimenting its an uncontrollable habit of mine he he
