Nerf Football Sabot for Potato Cannon or XE-15 CAT

Ive designed this to tackle a problem ive been running into when using my XE-15 CAT launcher with CO2 40mm Avenger shells. The issue is the destruction of the fins on use. I would get one maybe two firings before the fins would be completely trashed and the nerf rocket unusable. When you look at existing foam rocket launchers like the Metadyne Havoc they use regulated CO2 at 200ish PSI. Well these airsoft shells dont, they dump all 800-900 PSI instantly and it is VERY destructive. So it makes perfect sense that the fins would be trashed by such a force. 

Enter my sabots. 

It took several redesigns and prototypes, this one is the final iteration, V7, that will survive multiple firings without failure. All previous models would be destroyed by firing. But this V7 sabot will go dozens of firings as long as you dont shoot it into a hard surface like concrete. That said, them falling onto concrete after firing is just fine. They do survive that. 

This is designed for the American 2inch model of XE-15 CAT so it fits US standard Schedule 40 PVC 2in pipe. The fit is tight, so the rockets are retained in the launcher even if carried in a game muzzle down. On firing, the sabots will discard anywhere between 10 and 30 yards. I have successfully superglued on thin strips of plastic from things like milk jugs and pop bottles onto the sides of the sabots, between the reinforcement ribs, so they open up when air pressure peels them back, just like the wads used in shotshells. That causes them to discard much sooner but takes a bit of extra work and experimentation. 

I have printed this in both standard Bambu PLA and PETG HF with excellent results. Though I HIGHLY recomend you use neon/vibrant colors. I only have OD Green PETG on hand at the moment, and even in my yard they can be difficult to find reliably after firing. In an airsoft field, I would expect to lose quite a few if printed in earth or camo colors like green, brown, tan, or black. So make sure you use something that stands out. Blue, red, orange, yellow, white (unless in winter) ect. 

My personal recomendation is to use PLA since bio bbs are composed of the same. This satisfies most fields requirements that BBs be bio, so if you lose a sabot or one breaks into pieces, its bio and not going to cause an issue long term. I know they arent BBs, but it should put field owners at ease at least a little bit. That said, do NOT fire these at people. Vehicles and bunkers ONLY. They hit HARD. Total max range ive gotten so far is 300+ feet, if that gives you an example. This from a stubby barrel where the tip of the rocket sits an inch back. With a longer tube, id expect even more. 

Im printing with 
3 wall loops
5 top shell layers

6 bottom shell layers

50% infill rectilinear 

Youll see in my pictures that my shell has been drilled with 8 large holes. This was to try to cut down on the impact from the gasses hitting the base of the sabot in earlier versions. Its easy to do, and evens out impact forces. I do have a new shell coming in the mail and will test these sabots with that and edit this post with the results.