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Cattle Haul. The SpaceX engineers would work for ten days straight, come back to California for a weekend, and then head back. To ease the burden of travel, Musk sometimes let them use his private jet. “It carried six people,” Mueller said. “Well, seven if someone sat in the toilet, which happened all the time.” While the navy and Beal had left some testing apparatus, SpaceX had to build a large amount of custom gear. One of the largest of these structures was a horizontal test stand about 30 feet long, 15 feet wide, and 15 feet tall. Then there was the complementary vertical test stand that stood two stories high. When an engine needed to be fired, it would be fastened to one of the test stands, outfitted with sensors to collect data, and monitored via several cameras. The engineers took shelter in a bunker protected on one side by a dirt embankment. If something went wrong, they would look at feeds from the webcams or slowly lift one of the bunker’s hatches to listen for any clues. The locals in town rarely complained about the noise, although the animals on nearby farms seemed less impressed. “Cows have this natural defense mechanism where they gather and start running in a circle,” Hollman said. “Every time we fired an engine, the cows scattered and then got in that circle with the younger ones placed in the middle. We set up a cow cam to watch them.” Both Kestrel and Merlin came with challenges, and they were treated as alternating engineering exercises. “We would run Merlin until we ran out of hardware or did something bad,” Mueller said. “Then we’d run Kestrel and there was never a shortage of things to do.” For months, the SpaceX engineers arrived at the site at 8 A.M. and spent twelve hours there working on the engines before retiring to the Outback Steakhouse for dinner. Mueller had a particular knack for looking over test data and spotting some place where the engine ran hot or cold or had another flaw. He would call California and prescribe hardware changes, and engineers would refashion parts and send them off to Texas. Often the workers in Texas modified parts themselves using a mill and lathe that Mueller had brought out. “Kestrel started out as a real dog, and one of my proudest moments was taking it from terrible to great performance with stuff we bought online and did in the machine shop,” Mueller said. Some members of the Texas crew honed their skills to the point that they could build a test-worthy engine in three days. These same people were required to be adept at software. They’d pull an all- nighter building a turbo pump for the engine and then dig in the next night to retool a suite of applications used to control the engines. Hollman did this type of work all the time and was an all- star, but he was not alone among this group of young, nimble engineers who crossed disciplines out of necessity and the spirit of adventure. “There was an almost addictive quality to the experience,” Hollman said. “You’re twenty-four or twenty-five, and they’re trusting you with so much. It was very empowering.” To get to space, the Merlin engine would need to burn for 180 seconds. That seemed like an eternity for the engineers at the outset of their stint in Texas, when the engine would burn for only a half second before it conked out. Sometimes Merlin vibrated too much during the tests. Sometimes it responded badly to a new material. Sometimes it cracked and needed major part upgrades, like moving from an aluminum manifold to a manifold made out of the more exotic Inconel, an alloy suited to extreme temperatures. On one occasion, a fuel valve refused to open properly and caused the whole engine to blow up. Another test gone wrong ended up with the whole test stand burning down. It usually came to Buzza and Mueller to make the unpleasant call back to Musk and recap the day’s foibles. “Elon had pretty good patience,” Mueller said. “I remember one time we had two test stands running and blew up two things in one day. I told Elon we could put another engine on there, but I wasPDF Image | SpaceX and the Quest
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