X-20 Dyna Soar (part 4): What if?

Spring, 1980. On the long runway of Kennedy Space Center a horde of photographers stands around two small space planes together with one impressive big one behind them. One of the small planes is faded black all over, the other one looks like it is a child of the big one, although it is the other way around.
This photo-op is the last chance to see the two Dyna Soars and the result of their effort, the Rockwell Space Shuttle Orbiter OV101, together. The black Dyna Soar is shown in its former USAF livery. The black and white one is called Enterprise and the big Space Shuttle Orbiter is called Constitution.

More on the story and the build after the jump.

NOTE:
This is the LONG version of the story I conceived, and I don't care about people with the attention span of a chihuahua with ADHD, so buckle up. The photos will have comments below them about the build.

What-if…When Dyna Soars roamed the skies

The X-20 was conceived by the U.S. Department of Defense in the late 1950's. It was designed to become an orbital spy plane, much like the X-37b is now, maybe even a space bomber like the Silbervogel thought up by Eugene Sanger. In the time the X-15 was breaking altitude and speed records, the thought of an actual space-going orbital cousin was obvious. Several aerospace companies came with ideas and designs for such a plane. Boeing finally got the contract and started building a prototype in 1962.
Unfortunately, because of the ongoing space race, in which Project Mercury and Gemini thereafter were making a good point in capsules being cheaper, proven in action and in fact just as good as what Dyna Soar would be, senator McNamara cancelled the project in the end of 1963. The actual airframe, already being built by Boeing, which was 40% finished, was scrapped. End of story, curtain. Small applause. Footnote in history.

But. What if.
What would have happened if the project would have continued. Keeping in mind that in the late 60's NASA (and the DOD) actually were looking for a reusable (and winged) solution to their expensive space program and the data obtained by the X-15 was considered very helpful in designing this new spacecraft, what would have happened if Dyna Soar actually flew? Let's just roughly sketch a fictitious timeline here.

Dyna soar alternative timeline

In 1963 Gemini developments were well on its way. It yet had to be flown but still, evidence seemed this craft would be more than capable of also functioning as a great spying platform. In the Senate, McNamara announces he'd like to cancel Project Dyna Soar in favour of researching military Gemini options. Immediately, he gets some resistance from NASA executives. Spaceflight, they now know, turns out to be really expensive. A study concerning a reusable spacecraft would be welcome. There may be some good use for that in the near future. So, McNamara eventually only decreases the budget for the Dyna Soar project. There will be only 2 ships built and they will be for testing and research purposes only. So, Boeing continues the development of Dyna Soar (DS) Ship 1. The emphasis will be on reusability. Its main task in space will be manoeuverability and re-entry flight pattern tests.

The second Dyna Soar in NASA outfit. White parts made of Canvas textured paper, black parts (tiled) are smooth.
Visible is the top window for the co-pilot. Yes, this Dyna Soar is a two-seater.

I actually love the texture. It looks really cool and gives the plane the look I hoped it would get.

Soon, still in 1963, Boeing also starts building DS2, which will be a two-seater. In the end of 1963 the finished DS1 is transported to Edwards AFB and readied for test flights.

During 1964, DS1 undergoes ground and flight tests. Flights consist of drop tests from the wing of a B-52. All tests are performed on Edwards AFB. Mid-year the first powered high-atmosphere flights with an add-on rocket engine take place. DS1 holds well and performs good. DS2 development goes according to plan.
Also in 1964, two boilerplate full scale, full-weight Dyna Soars are successfully test launched with a Titan IIIC booster from KSC. Tests are done for flight characteristics of the complete stack and stress measurements of the test article itself during ascent. Flight article 1 is suborbital and saved (parachute in ‘payload bay’ canister), flight article 2 makes a couple of orbits before it intentionally burns up on re-entry over the Pacific. Meanwhile, flight tests of DS1 continue, also to get pilots to know the ship.

Dyna Soar on a modified Titan 2. Source: Wikipedia

It's 1965 and the first manned launch and successful suborbital flight of DS ship 1 takes place in early june. From a Vandenberg launch site. The modified Titan 2 flies up to 110 KM before Dyna Soar 1 separates, experiences microgravity in the top of the parabola, falls back and re-enters like the X-15 before her did. Only from higher up – and faster. DS1 approaches very fast and makes a couple of steep S-shaped turns to bleed off speed. This beforehand suggested theory actually turns out to be very effective. DS1 lands on its skids at Edwards AFB, accompained by three F-104 Starfighters.

The build actualy was quite easy, although there was more cutting with separating the black
and white partsfrom their respective sheets and joining them together as tightly as possible.

 
DS2 is readied and paced through the tests a lot faster but just as thorough.

The first successful launch into orbit of DS1 is in November. From the Cape DS1 is launched on a Titan III, spectacularly aided by the two large solid boosters. Three full orbits are made and upon re-entry, there is only the expected superficial and foreseen damage to the heat shield. The launch and flight itself is covered by television.

Image: © Buran.ru

In 1966, DS1 is launched to orbit two times, both times successfully. Both flights last two whole days with lots of tasks set out for the pilot. DS ship 2 has its first two-crew suborbital test launch from Vandenberg planned on a Titan 2 later that year. Despite the reasonably successful achievements so far, DOD still announces their deisinterest in the X-20 project due to costs (the Vietnam war has started and needs lots of DOD funcing) and a fading interest in its value. Mainly because new spysats have proven to be a just as reliable and certainly a much cheaper platform for spy photography. The rest of the DS testflights are immediately cancelled. NASA being unable to carry the costs alone, has to step back too. Ships 1 and 2 are preserved and stored in a hangar at Edwards AFB, awaiting decommissioning and an inevitable eventual scrapping.

1967 and 68 pass. Nothing happens. DS1 and DS2 are stored under a blue tarp in a well - secured hangar. Meanwhile, Apollo takes flight. But in the end of 1968 NASA already starts to feel the first results of budget cuts. They start to look for a cheaper solution to go to space after Apollo. A reusable spacecraft, preferably in the shape of a plane indeed seems the best solution after all. The Space Task Group is initiated for the program that soon will be called The Space Shuttle program.

They need test equipment and experience in reusability. Theories are all very nice, but how would a real reusable spacecraft fuction over time?

NASA immediately shows interest in taking over DS ships 1 and 2 for research and testing purposes and obtains both ships spring 1969. In spite of the well-prepared storage, the ships are in an all but flight ready state. Ship 1 is in need for repairs due to some leakage in the fuel lines and some electronic malfunctions. Boeing is put to work.

Ship 2 however, is ready to go. It immediately is used for atmospheric drop tests in early Shuttle flight characteristics and landing methods with NASA’s B52. (consequently, due to the shape and size of the X-20, the X-24 is not rebuilt as the X-24B in this alternate timeline and remains the chubby little potato-plane it alwasy was.)

An airlock? a docking ring? Who knows?

In 1970, both DS1 and DS2 make zoom flights to the upper atmosphere from B52 using add-on rockets to study flight characteristics of delta winged aircraft on re-entry trajectories. Discussions are underway for thorough modifications on both ships and manned space flights on man-rated Titan IIIe's. After some final hurdles, it's all “go” and NASA orders a couple of Titans for this purpose.

In 1972, Apollo 18-20 are definitely cancelled, the Shuttle-project is given a "go". Now there finally is more budget for speeding up the tests with the X-20's. DS1 continues as trainer in Approach and Landing Test flights. Also they will use the ships to test new heat-resitant material for in-orbit and during re-entry. Because of their now new function of pathfinders for the Rockwell Shuttle, NASA decides to name the ships and involves the public in the decision. DS1 is named Kitty Hawk, ship 2 will be named Enterprise, after lots of Star Trek fans get involved in the naming. DS2 (Enterprise), will be first to receive its new outer skin while tests with DS1 (Kitty Hawk) continue.

Elevon / body flap, left black, and tiled underneath.

Port stabilo, combined canvas textured and regular paper. The RCC leading edge is curved here
and protects the side and the underside of the stabs.

The starboard stabilo in the making. The grey is the glueing strip section on the inside.
It also reinforces the RCC leading edge of the  stab.

It's 1973. While DS1 Kitty Hawk is getting its necessary overhaul, DS2 Enterprise has gotten its dark tiled heat shield belly and white thermal shielding top layer. In nice black letters in a clean Helvetica font, the name is painted behind the cockpit window. Those windows, by the way, now are the same construction as the soon-to-be Rockwell Shuttle and so now it really is looking like a small Rockwell Shuttle. There is no need for the window shield any more. The most innovative is the leading edge. I'ts made from Reinforced Carbon Carbon, RCC for short, which is the best way of heat protection for the upcoming Space Shuttle, they have theorised. Atmospheric flight tests with the new seating configuration and shielding start immediately and are successful. All equipment intended for use on the Shuttles is thus being tested in the real. After its overhaul, DS1 Kitty Hawk too is refitted with new skin and after a couple of landing tests, ready to fly again. Both ships are tested in heat chambers, freeze rooms and thoroughly shaken. The tiles on Enterprise deem to fall off here and there and hastily a new compound is created for glueing the ceramic tiles.

In the summer of 1974, after waiting 8 years, DS2 Enterprise is finally launched into orbit on a Titan IIIC with a transtage. It performs brilliantly with its new computer system, the shielding holds well in re-entry. Some of the white upper fuselage thermal tiles are lost on the upper structure but they are no cause for worry. A second launch happens later that year. Because of the aforementioned upper fuselage tile loss, Kitty Hawk bears another experimental type of insulation; instead of white tiles, it has a much lighter thermal blanket covering its upper side. Soon thereafter, Enterprise too gets a thermal blanket top surface.

Meanwhile, building on Rockwell Shuttle OV-101, soon to be named “Constitution” by NASA, has started in June of 1974. The experiences with the two X-20s are immediately incorporated in the Rockwell shuttle. The new compound for attaching the tiles and the upper thermal protection blankets are there from the beginning. The nose and cabin section get a dark appearance, just like the small Dyna Soars.

Between 1975 and 1979, 12 flights are made with the DS ships. Enterprise makes 7, Kitty Hawk makes 5. DS Kitty Hawk is mainly used for testing materials and re-entry flight paths for the Rockwell Shuttle. DS Enterprise has a meticulously planned rendezvous with the abandoned Skylab on its 4th flight in 1977 and with it, it proves the maneuvering abilities of the ship. The 5th flight of Kitty Hawk gets hairy very quickly: Due to a computer error the re-entry becomes very steep and almost ballistic. Only because of a lot of stick and rudder work, luck and knowledge of orbital mechanics the Dyna Soar pilot manages to complete the re-entry in one piece. When it emerges from the fireball it appears to be in good shape. However, it overshoots its initial landing spot at Edwards AFB and that causes the ship to have to use the emergency landing strip at White Sands.
Upon landing one of the skids won't come out and it results in a controlled all skids up belly landing. The astronauts escape without serious injuries and Kitty Hawk has not broken up, but the airframe suffered a lot of damage by the fine sand, in fact too much to resume flight any time soon. Upon return to the Cape, the decision is made to permanently ground Kitty Hawk.
Enterprise finishes the rest of its planned flights, plus some of Kitty Hawk's designated flight projects, the last being in january 1979. Because the end of the tests is in sight, NASA already anounces plans to give away the two ships. NASM and the Air Force Museum are of course interested.

A trolley to transport the landed Dyna Soar back to the hangar. The idea was to make it low enough, so that it can be rolled underneath the spacecraft from behind. The trolly then will be hydraulically raised to a level that the pads on the trolley lift the ship off the ground. It then can retract the skids. A tractor then will pull the trolley with the Dyna Soar back to the hangar.
I think I only partially succeeded, the design is far from practical, I think. It looks good but in a more or less Thunderbirds-fashion and not really USAF or NASA. I first had a much simpler V-shaped version in my mind, but the nose skid is placed so far forward, that I wouldn't get the beams underneath. And so the trolley had to roll under the Dyna Soar from behind.

With the aid of the National Air Force Museum in Dayton Ohio and NASA, the grounded Kitty Hawk is cosmetically restored to its former glory as DOD ship with its original USAF appearance. The damaged tile surface is carefully removed and the dark Inconel skin is cleaned.
In the meantime in 1977, OV-101 "Constitution" has successfully completed its Approach and Landing Tests. With it, the research that was needed for the shuttles is completed. Having served as test beds for a lot of shuttle materials, the Dyna Soars' efforts were used in making OV-101 a completely space worthy Shuttle: Thermal blanket, tiled belly, real engines and computer systems. The Dyna Soars also significantly sped up the development of the building of OV-102, Columbia, which is nearing completion in spring 1978. It's 1979, July 11th, exactly 10 years after the launch of Apollo 11, when Space Shuttle OV-101 Constitution lifts off from LC39A on its maiden trip. It is piloted by Gemini and Apollo veteran John Young and Dyna Soar veteran Bob Crippen. The flight is successful. Crippen pays a nice tribute to the two little Dyna Soars during the flight. In late December of that same year, Columbia makes her first flight.

In the spring of 1980, Dyna Soars Kitty Hawk and Enterprise are officially retired. The Smithsonian gets Enterprise, the National Air Force Museum in Dayton gets Kitty Hawk. In a carefully planned goodbye ceremony, Both ships are rolled to KSC's runway one last time for a final photo-op. Kitty Hawk in its new "old" look and Enterprise in its now well known and well-worn NASA-livery. Not entirely coincidentally, Shuttle Constitution has returned for the third time from space the day before, and NASA takes this opportunity to put all three spacecraft together on the ramp for a unique family photo opportunity. After that, Constitution is rolled back to the OPF, and the Dyna Soars are carefully loaded into a C-5 Galaxy waiting further down the runway and consequently delivered to their respective final homes in DC and Ohio.

A nice little blue flashlight on top of a pole would be a good ides for such a trolley. So there. And a cool box with buttons.

And Enterprise fits well on its trolley. Now for some beauty shots.

 

 

A plastic 1/48th WW2 pilot for scale.

 

Well, that was it. I might once do a 1/144 Constitution shuttle which fits this storyline one day, and I also might once do a Titan IIIc with this Mark Cable Dyna Soar model on top, but for now I think it has been enough Dynasoarcery. Now I will be doing something new of which I yet have no idea of what it will be.

See you next time and thanks for stopping by. Stay safe.

--PK