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The uprated Saturn I Quarterly Film Report
Number 28 covers progress during het period

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April, May, June 1966.

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In preparation for the launch of AS-203, the
Chrysler-built booster for the second uprated

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Saturn I launch vehicle was whipped from Marshall’s
Michoud Facility on April 7.

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It Arrived at Cape Kennedy five days later.

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It was moved into hanger AF for pre-erection
inspection and checkout.

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On April 18, the stage was erected on LC 37B.

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On April 4, the Douglas-built second stage
was flown from the west coast to Cape Kennedy,

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marking the first delivery of flight-type
second stage aboard the Super Guppy.

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On April 14, the instrument unit was flown
from Marshall to the Cape aboard the Super

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Guppy.

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The nosecone was barged from Marshall to KSC
aboard the Poseidon last quarter.

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On April 21, the second stage, instrument
unit, and nosecone were attacked atop the

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booster.

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Prelaunch activities for AS-203 then got underway
and continued through the quarter.

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The prime mission of AS-203 will be to place
the second stage with about ten tons of liquid

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hydrogen into ta circular orbit of 100 nautical
miles.

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This will allow Marshall space scientists
to study the dynamics of liquid hydrogen under

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weightlessness and verify that the stage’s
engine can be restarted in orbit.

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Objectives of the tests include determining
if the continuous venting system and thrusters

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will properly seep the liquid hydrogen in
the bottom of the tanks and if the engine

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can be adequately chilled down to simulate
Saturn V S-IVB orbital operations.

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At Marshall’s System Development Facility,
in unison with Launch Preparations at Kennedy

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Space Center, work efforts continued on development
and verification of the computer program tapes

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of automatic checkout of AS-203.

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AS-203 is scheduled for launch on July 5.

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Following completion of vehicle erection at
Launch Complex 34 last quarter, SA-202 continued

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in preflight checkout throughout the report
period.

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AS-202 launch is planned for next quarter.

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Its mission will be to launch the Apollo spacecraft
into suborbital flight ending in the Pacific

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Ocean near Wake Island.

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During reentry, the spacecraft ablative heat
shield will be tested under the high heat

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loads of reentry.

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At Marshall’s Michoud Assembly Facility,
Chrysler completed post-static checkout May

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25 on the booster for the fourth flight vehicle.

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The stage is scheduled for shipment to the
Cape next quarter.

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Following he second successful static firing,
a leak was detected inside the thrust chamber

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on engine position number four of the fifth
flight booster.

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Investigation revealed a horizontal crack
in a tube about ten inches below the injector

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face.

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The engine was removed and shipped to Rocketdyne
Neosho for a repair.

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The booster was shipped back to Michoud on
April 7, arriving six days later.

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Modification was performed, including replacement
of the repaired engine, and post-static checkout

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began on May 31.

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Pre-static checkout of the six flight vehicle
booster was completed early this quarter.

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The stage was shipped to Marshall from Michoud
May 19, arriving May 28.

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It was installed in the Static Test Stand
May 31.

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A short-duration firing was conducted June
23, followed by a long-duration firing June

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29.

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This test series marks another milestone in
the Saturn IB Program since the Rocketdyne-built

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engines have been uprated to 205,000 pounds
thrust.

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No problems were encountered except for a
thrust chamber leak on one engine, which necessitated

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engine removal for a repair.

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A replacement engine was installed to preserve
schedule, and the stage is undergoing preparation

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for shipment to Michoud, planned for next
quarter.

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Assembly of the first stage for the seventh
flight vehicle was completed in mid-quarter.

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Pre-static checkout got underway May 31, about
two and one-half weeks ahead of schedule.

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Checkout is scheduled for completion early
next quarter.

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Fabrication of the eighth flight booster was
completed early this quarter.

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Stage assembly started April 14 and is scheduled
for completion early next quarter.

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Fabrication of the ninth flight vehicle was
completed in June.

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Assembly is underway.

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Also at Michoud, fabrication of the tenth
flight vehicle was started in early April

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and continued throughout the report period.

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Chrysler has only two more boosters remaining
to be manufactured under the present contract.

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All of the long lead time items for these
two have been procured.

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First stage LOX tank qualification testing
continued early this quarter by Chrysler at

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Michoud.

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Both the seventy inch and the 105 inch tanks
were tested to 125 percent design load, meeting

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test completion deadline and requirements
for SA-203.

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Additional testing is being conducted to qualify
the tanks to 140 percent design load for manned

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flight reliability.

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The 105 inch LOX tank has been tested to 140
percent of design load under all condition

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except two.

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The seventy inch tank has been qualified under
all conditions except maximum thin load.

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Meanwhile, at Douglas’ SACTO Facility, the
second stage for the fourth flight vehicle

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underwent modification, rework, and post-static
checkout at the vertical checkout laboratory.

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The stage was accepted by Marshall at SACTO
on May 6.

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Shipment to Cape Kennedy will be next quarter.

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The second stage for the fifth flight vehicle
was shipped from Huntington Beach to SACTO

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April 9.

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On April 13, the stage was installed in the
Beta 3 Test Stand where pre-static and subsystem

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checkout proceeded at scheduled.

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Following a successful 440second acceptance
firing on June 2, post-static checkout was

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completed June 28.

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Following installation of the J-2 engine in
April for the sixth flight vehicle second

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stage and factory checkout completion in late
May, final inspection was made and the stage

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was shipped to SACTO June 30.

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In April, Douglas completed joining of the
thrust structure and forward and aft skirts

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of the second stage of the seventh flight
vehicle and installed the engine in May.

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Factory checkout was started and continued
through the report period.

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Completion of checkout is scheduled for early
next quarter.

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The second stage of the eighth flight vehicle
was removed from the insulation chamber on

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June 6.

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Necessary cleaning and miscellaneous parts
installations were completed in June.

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Factory checkout will take place next quarter.

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Manufacturing was completed on the common
bulkhead for the second stage of the ninth

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flight vehicle at Santa Monica.

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Welding of the liquid hydrogen tank segments
and LOX tank assemblies was completed and

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the LOX tank was shipped to Huntington Beach
June 16.

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Stage assembly will be completed next quarter.

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Fabrication of the tenth flight vehicle’s
second stage was started last quarter and

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was drawing to a successful close at the end
of this report period.

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Assembly and miscellaneous testing is planned
for next quarter.

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On April 13 at SACTO during S-IVB structural
testing, the common bulkhead and LOX tank

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failed.

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The failure is being thoroughly investigated
by Marshall and Douglas personnel.

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However, subsequent structural testing on
the hydrostatic test tank specimen qualified

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the design.

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At IBM Huntsville, component installation
in the fourth flight instrument unit, started

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last period, was completed the first week
in May.

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Checkout began in May and was completed on
June 28.

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The unit will be shipped from IBM to the Cape
early next quarter.

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The fifth flight IU structural fabrication
started last quarter was completed May 4.

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Component installation was begun ten days
later with completion planned for next quarter.

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Also at IBM Huntsville, structural fabrication
was started for the sixth flight instrument

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unit.

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At Marshall, work effort is underway for in-house
manufacture of four uprated Saturn I nosecones.

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These units will be carried atop the vehicles
which will place lunar modules into orbit.

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In late April, ten astronauts visited the
Marshall Center for briefings on the uprated

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Saturn I Program.

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Among the group are the three men who will
fly the first manned Saturn, Apollo 1B Mission,

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Virgil Grissom, Command Pilot, Edward White,
and Roger Chaffee.

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The astronauts were given briefings, including
primary hardware description and design philosophy

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by Saturn engineers and management officials.

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The astronauts also studied flight data on
the performance of the first uprated Saturn

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I, which launched an unmanned Apollo spacecraft
last quarter.

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A summary of the Saturn IB program through
the months April, May, and June shows major

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accomplishments in all areas, continued buildup
of Saturn IB stages and equipment, acceleration