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SpaceX’s first high-altitude Starship gets ready to prove itself

SpaceX has begun installing functional aerodynamic control surfaces on a Starship prototype for the first time. (NASASpaceflight - bocachicagal)

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SpaceX has begun outfitting its first high-altitude Starship prototype with the basis of functional aerodynamic flaps, potentially paving the way for the ship’s first crucial proof test(s) in the near future.

Unsurprisingly, the first real attempt to install the functional ‘flaps’ Starships will use to fall back to Earth and land has been (relatively) slow going. The tank and engine section of Starship serial number 8 (SN8) – the high-altitude prototype-to-be – was stacked to its full height around August 27th. Shorthand for curved steel sections meant to make Starships more aerodynamic and protect sensitive mechanisms, the first signs of functional ‘aerocovers’ arrived in Boca Chica a few days later on August 31st.

Aerocover ‘caps’ arrived in Boca Chica in mid-August. (NASASpaceflight – bocachicagal)
Long shrouds arrived in mid-September. (NASASpaceflight – bocachicagal)
A possible aerocover installation jig or flap frame. In the foreground, SpaceX already has several pairs of flaps on hand whenever SN8 is ready for them. (NASASpaceflight – bocachicagal)

A much longer aerocover appeared on September 11th and SpaceX appeared to begin installing it on Starship SN8 around September 14th, temporarily tack-welding it to the rocket’s hull. SpaceX may be using a sort of alignment jig (bottom photo above) to ensure that the extremely thin and flexible steel covers are easily installed in a uniform fashion where they’re supposed to be.

If not, the LEGO-esque structure could also be a rudimentary frame for Starship’s aft flaps – heavy and inefficient but extremely cheap and easy to build and tweak. Most of that work is being done inside SpaceX’s Starship assembly building, largely hidden from sight from public perspectives, so it’s hard to say anything with certainty until SN8 rolls out for the first time.

A closer view of the Starship SN8’s first aerocover. (NASASpaceflight – bocachicagal)
Starship SN7.1 is still awaiting its destructive end. (NASASpaceflight – bocachicagal)
SpaceX is already preparing for what comes after SN7.1, however. (NASASpaceflight – bocachicagal)

When that milestone will come is unclear, likely to the extent that even SpaceX isn’t sure. Currently, it’s unknown if SpaceX will fully outfit Starship SN8 with a nosecone and all four flaps before putting the prototype through its first proof tests – possibly up to and including the first static fire test with three Raptor engines. Starship SN8 is the first full-size prototype built out of a new steel alloy and while that alloy is currently being tested to its limits by test tank SN7.1, proving SN8’s integrity first would save a lot of time and effort in the event that SpaceX has more to learn about the limits of 304L steel and the ship fails during basic testing.

If SpaceX chooses to perform a cryogenic proof test prior to fully installing flaps and a nosecone, Starship SN8 could feasibly roll to the launch pad well before the end of the month. In fact, SpaceX moved a hydraulic ram used to simulate Raptor thrust back to the main test stand – where SN8 will likely undergo its first tests – on September 19th. Typically, that ram has been installed just days before a Starship is transported from factory to launch pad.

In the event that SpaceX chooses to perform a cryo proof test and/or static fire prior to fully integrating Starship SN8, the ship could likely be easily moved back to the factory to have its nosecone and flaps installed. Either way, chances are good that SN8 will be ready to head to the launch pad for its first test campaign within the next two weeks.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Armored Tesla Cybertruck “War Machine” debuts at Defense Expo 2025

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Tesla Megapacks chosen for 548 MWh energy storage project in Japan

Tesla plans to supply over 100 Megapack units to support a large stationary storage project in Japan, making it one of the country’s largest energy storage facilities.

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Credit: Tesla

Tesla’s Megapack grid-scale batteries have been selected to back an energy storage project in Japan, coming as the latest of the company’s continued deployment of the hardware.

As detailed in a report from Nikkei this week, Tesla plans to supply 142 Megapack units to support a 548 MWh storage project in Japan, set to become one of the country’s largest energy storage facilities. The project is being overseen by financial firm Orix, and it will be located at a facility Maibara in central Japan’s Shiga prefecture, and it aims to come online in early 2027.

The deal is just the latest of several Megapack deployments over the past few years, as the company continues to ramp production of the units. Tesla currently produces the Megapack at a facility in Lathrop, California, though the company also recently completed construction on its second so-called “Megafactory” in Shanghai China and is expected to begin production in the coming weeks.

READ MORE ON TESLA MEGAPACKS: Tesla Megapacks help power battery supplier Panasonic’s Kyoto test site

Tesla’s production of the Megapack has been ramping up at the Lathrop facility since initially opening in 2022, and both this site and the Shanghai Megafactory are aiming to eventually reach a volume production of 10,000 Megapack units per year. The company surpassed its 10,000th Megapack unit produced at Lathrop in November.

During Tesla’s Q4 earnings call last week, CEO Elon Musk also said that the company is looking to construct a third Megafactory, though he did not disclose where.

Last year, Tesla Energy also had record deployments of its Megapack and Powerwall home batteries with a total of 31.4 GWh of energy products deployed for a 114-percent increase from 2023.

Other recently deployed or announced Megapack projects include a massive 600 MW/1,600 MWh facility in Melbourne, a 75 MW/300 MWh energy storage site in Belgium, and a 228 MW/912 MWh storage project in Chile, along with many others still.

What are your thoughts? Let me know at zach@teslarati.com, find me on X at @zacharyvisconti, or send us tips at tips@teslarati.com.

Tesla highlights the Megapack site replacing Hawaii’s last coal plant

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Elon Musk responds to Ontario canceling $100M Starlink deal amid tariff drama

Ontario Premier Doug Ford said, opens new tab on February 3 that he was “ripping up” his province’s CA$100 million agreement with Starlink in response to the U.S. imposing tariffs on Canadian goods.

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NORAD and USNORTHCOM Public Affairs, Public domain, via Wikimedia Commons

Elon Musk company SpaceX is set to lose a $100 million deal with the Canadian province of Ontario following a response to the Trump administration’s decision to apply 25 percent tariffs to the country.

Starlink, a satellite-based internet service launched by the Musk entity SpaceX, will lose a $100 million deal it had with Ontario, Premier Doug Ford announced today.

Ford said on X today that Ontario is banning American companies from provincial contracts:

“We’ll be ripping up the province’s contract with Starlink. Ontario won’t do business with people hellbent on destroying our economy. Canada didn’t start this fight with the U.S., but you better believe we’re ready to win it.”

It is a blow to the citizens of the province more than anything, as the Starlink internet constellation has provided people in rural areas across the globe stable and reliable access for several years.

Musk responded in simple terms, stating, “Oh well.”

It seems Musk is less than enthused about the fact that Starlink is being eliminated from the province, but it does not seem like all that big of a blow either.

As previously mentioned, this impacts citizens more than Starlink itself, which has established itself as a main player in reliable internet access. Starlink has signed several contracts with various airlines and maritime companies.

It is also expanding to new territories across the globe on an almost daily basis.

With Mexico already working to avoid the tariff situation with the United States, it will be interesting to see if Canada does the same.

The two have shared a pleasant relationship, but President Trump is putting his foot down in terms of what comes across the border, which could impact Americans in the short term.

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