Red Star: A Soviet Lunar Landing

With the American Project Apollo in jeopardy, the Soviet Union was quick to take all the advantage that they could from it - not publicly stating this act, of course - and set to work on the next major milestone in their Manned Lunar Programme. The Soyuz 7K-L1 Manned Circumlunar Flights - codenamed ‘Zond’ to help hide its nature - was coming to fruition. Comprising of the Soyuz Re-Entry Module and the Service Module, both lightened to reduce the mass to a level that the N11 Launch Vehicle and Block D would be able to cope with. Though this saw the deletion of the Reserve Parachute and some of the propellant, it was felt that the improvements being made to the Soyuz (of which the L1 was derived from) would allow for it.

In the March of 1967, an N11 launch vehicle carried the 7K-L1 and Block D safely into Earth Orbit, following which the Block D was ignited, taking the Spacecraft well away from the Moon, as was planned, since this first test flight was to assess the ability of the capsule to function at Lunar Distances, through the Earth’s Radiation Belts and beyond its Magnetosphere. This flight passed all its requirements and allowed for the next group of flights to take place.

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The Soyuz 7K-L1, 'Zond'

In fact, just two months later, they were ready with their next attempt. Again, the N11 performed well, and this time, the 7K-L1 was placed on a proper Trans-Lunar Trajectory, conducting one loop around the Moon, during which the new guidance system was tested (chiefly its star tracker and sun tracker), which would be a necessity for the future Soyuz-LOK flights.

There were problems encountered with the flight, while the sun tracker was performing properly, the star tracker was stubbornly failing to acquire Sirius, though the first and second mid-course manoeuvres weren’t entirely necessary, it would be vital for the return leg (and the third planned mid-course burn) to keep the capsule from bouncing back into Space. Repeated attempts under various settings were conducted to try and acquire Sirius for the final required mid-course burn, and finally, through a high-density filter setting, they were finally able to correctly orient the spacecraft and make the required course-correction, which was good enough to not need any further corrections.

As the spacecraft re-entered, a slight error with the re-entry guidance programme meant that while the L1 did perform a good skip re-entry, it was sent off-course from its targeted landing site by some significant margin, almost 300 Km East, North-East with higher than predicted re-entry G-Forces. Nonetheless, OKB-1 - which by now had been renamed TsKBEM - decided that none of the problems detected in the flight would be particularly difficult to resolve, and they could be ready for the next attempt at its planned July attempt.

But while the N11 and Zond were performing quite well, the N1 was still facing serious “teething issues”, and had been grounded for 10 months as they worked to resolve the problems that the first test flight had highlighted when it had failed. It was a late June morning when the next N1 sought to prove that it was up to the job..

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Again, for over 120 seconds, the flight performed well, but as a pre-programmed command to shut down some of the engines early - to prevent an overstressing of the stage structure - was given, sensors showed Pogo Oscillations building up in the N1, if they grew too powerful, they could tear the entire launch vehicle apart. For 25 stressful seconds, the ground crew watched the readings grow worse and worse, the N1 was ins serious danger of breaking itself apart. Finally, the order was given to fire the Block B early and shut down the Block A, hoping that that would be able to halt the POGO event. Fortunately, the gamble worked. As the Block B continued to climb, the flight parameters were returning to their normal levels, and less than 11 minutes into the flight, the N1’s mock-payload was safely in orbit, if a little lower than its planned 225 Km circular (204x186 Km).

This didn’t stop the Soviet State Media from announcing that the N1 had succeeded in its goal of placing a test payload into Low Earth Orbit - again, not exactly a lie - and that it gave them unprecedented capability with regards to their spaceflight programme. NASA, and the whole of the Western World, could only assume that the Soviets were ahead, and needed to step up a few gears. What they didn’t know, was that the Soviet Lunar Landing effort was still being held back by the need to re-work their Soyuz to make it safe for flight, and a critical component that hadn’t even been test-flown yet.

The July and September of 1967 witnessed the next pair of unmanned Zond flights (5 & 6). While both did manage to complete their missions, Zond 5 had seen the re-entry guidance fail again and force the capsule into a harsh ballistic re-entry that splashed down in the Indian Ocean, while Zond 6 had been forced to eat through all its available propellant to get it into the correct re-entry window. Even so, Mishin had decided that with all the errors and faults identified and rectified (and besides, the living payloads that they had carried had survived), they could safely send crew on a Manned Circumlunar Mission. And while it was true that they had missed the 50th Anniversary of the Bolshevik Revolution, they did still hold a lead over the USA, which was enough, for enough of the Soviet Leadership.

The November, however, saw NASA prove that they weren’t out of the race. To try and make up for lost ground, this first test flight of the Saturn V would be an all-up test, with the Saturn S-IC and S-II being fired for the first time in full flight conditions, the first time that the S-IVB would be re-started, and the first time that the Apollo CM would re-enter at Lunar Re-Entry velocities.

In the early morning, the Saturn V’s 5 F-1 engines roared into life, sending shockwaves of noise far greater than expected in all directions, buffeting the VAB, the Launch Control Centre, and the press building, all located at least 3 miles away to protect them from possible on-the-pad explosions of the Saturn V.

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This first test flight for the Saturn V was flawless, placing the unmanned Apollo CSM into the correct Parking Orbit of 100nm. Two orbits later and the S-IVB successfully reignited, sending the spacecraft onto its new Apogee of 9,297nm with a perigee of -45.7nm to ensure atmospheric entry of the CSM and the destruction of the S-IVB. As the Apollo Spacecraft ascended, it fired its own engine to raise the apogee further, and again to increase its re-entry velocity to 36,545fps to simulate a Lunar return. A little over 8.5 hours after the mission began, the Apollo capsule splashed down less than 10nm from its target landing site, where the USS Bennington was waiting for it. It was a much-needed Morale Boost for NASA and the American Public, but it would also be a very short-lived one.


Note: IOTL, part of the reason for the problems that plagued the Soyuz 7K-L1 was that it was started in late 1965, not late 1962, the extra three years providing the time needed to get it working to an acceptable standard.
 
The successful Soyuz 2, 3 and 4 flights along with the near-perfect performance of the Soyuz 7K-L1 on previous unmanned tests had given the engineers and scientists at OKB-1 enough confidence that they approved the L1 as man-rated and ready to perform Human circumlunar launches. The N11 was rolled out to the launch pad in quiet secrecy while rumours around the world buzzed out a supposed planned Piloted Lunar flight. Most claimed it was going to be a circumlunar mission but some went so far as to say it would be Orbital considering the successful NI launch in October.

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As the cold air of Kazakhstan turned the elite spectator's breath visible the crew prepared for their most ambitious launch of their careers yet. Alexei Leonov was the obvious candidate for the Commander's seat as he was the one who could analyze and react to circumstances and emergencies best (like he did on his Voskhod-2 EVA when he was nearly stranded outside).

The roar of the N11's NK-15 engines was not uncommon or unheard and had echoed on the launch pad for over a year already. But know it signalled something other than communication satellites or unmanned test vehicles. Now it signalled the beginning of Humanity's first steps to another world. The intense acceleration and vibrations shook the cabin like it was about to fall to pieces. But it came nowhere near close to doing so, and following a few orbits to check all the spacecraft systems, the Block D upper stage powered the L1 spaceship on its planned circumlunar trajectory. Less than five minutes later, Leonov and Makarov were now coasting silently and inevitably towards to the Moon and back.

Over the three day voyage towards the Moon, Leonov and Makarov entertained the world with a live television broadcast of the L1 spaceship. While it was only four cubic meters in volume it was none the less larger than the Mercury or Gemini and quite functional for the short duration of the mission. The crew wore EVA/pressure suits at all times not just as a Spectacle for the viewers at home but also because of a lack of space in the capsule to store them.

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Day four of their Journey was a remarkable day. One that day the two cosmonauts and humanity with them entered the realm of Magic and Fairy tales only their magic was Science and Technology, on that day which lives in immortality December 19th 1967, the crew entered the gravitational influence of the Moon. The first thing humanity ever did around another world was to fall, faster and faster as the crew rounded the Moon. Ancient craters, plains, valleys and mountains all appeared closer than ever to the human eyes as if they were there, and indeed they were.

While the mission had begun as antagonism between Nationalities and Ideologies it grew it something much more than that, a growing perspective that we are one planet in the vast oceans of the Cosmos. Best represented by the famous "Earth Rise" photo taken as they came out of the far side of the Moon (a land long speculated and later mapped by probes but never seen by the human eye until now). The moment felt eternal.

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The Earth's irresistible gravitational attraction pulled the awe-struck pair ever onward having completed their loop of the Moon. Over another three days they saw the Earth growing ever larger, minute by minute. The failure of a minor electronic control unfortunately resulted in a near-disaster scenario for the crew, a slight error in the guidance programme that resulted from it resulting in the skip-re-entry of the spacecraft landing the vehicle severely off target. Luckily the L1 was designed to float, a very convenient design feature when your two hundred miles off the coast of Madagascar! The first Soviet splashdown was a very messy matter and was probably the most difficult recovery since the forest landing of Voskhod-2 (given the fact it was off by thousands of kms).

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The reaction of the Soviet people was one of hope and intense patriotism. It certainly reinforced the view that the Soviet Union was the most technologically advanced country in the world and that Communism would soon overtake the west in living standards. Even with Brezhnev in power the Khrushchev thaw and greater Freedom of Speech and Press still had a residual influence on Soviet Society. With Communist countries springing up in China, the winning North Vietnam, Eastern Europe and Cuba there was a growing sense that the Soviet path was the way of the future. Some Westerners predicted a Soviet lunar landing within the following year (1968).
 
I bet their is some harsh language in Houston and DC after this fiasco. The decision to go with a 3 man Capsule built by North American has come home to bite the US in the butt. They probably could have achieved Lunar flight in early 1967 using a Gemini Capsule and either a Saturn 1B modified with a 3rd stage like a Centaur or 2 Titan launches and rendezvous in Earth Orbit. Instead they are still fiddling with the Apollo Capsule and waiting for the massive Saturn V to finish testing.

Another great update.
 
I bet their is some harsh language in Houston and DC after this fiasco. The decision to go with a 3 man Capsule built by North American has come home to bite the US in the butt. They probably could have achieved Lunar flight in early 1967 using a Gemini Capsule and either a Saturn 1B modified with a 3rd stage like a Centaur or 2 Titan launches and rendezvous in Earth Orbit. Instead they are still fiddling with the Apollo Capsule and waiting for the massive Saturn V to finish testing.

Another great update.

Yes indeed. First the Apollo 1 fire, then Soyuz 2, 3 and 4 missions then the 2nd NII launch. Then Soyuz 7K-L1 circumlunar flight.
 
There will be a lot of bad surprise for NASA coming
the second Test flight of Saturn V aka Apollo 6, here it show it ugly site:
severe pogo oscillations by F-1 engine for 30 second, damage the LM simulator.
two J-2 engine of second stage had be shut down after they show problem and the S-IVB J-2 engine failed to restart.

Apollo 7 fight will have his problems with Crew complains, mission control harsh demands and a severe head cold on board
what let to a "Mutiny" in space.

The LM is not ready for flight, what make Apollo 8 flight useless, why copy the soviets ?

On N1 block A problem, it's seem that shut down engine Turbo-pumps, produce hell of vibration during running dry.
And that complex pipework is very vulnerable for this Pogo.
 
While most of the actual hardware and general management was assigned to Korolev’s OKB-1 Bureau (now TsKBEM under Mishin), the sheer scale of the N1 programme forced him to subcontract certain critical aspects of the project to other groups. One of these was Mikhail Yangel’s OKB-586 which was tasked with the development of the LK Lunar Lander.

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Soviet LK Lander as it would become (mostly)

Even at the very beginning before any actual hardware development was started, work on the LK Lander was plagued with problems, almost all of which was with regards to the Spacecraft Mass which had to be kept at or below 7,000 Kg while supporting two crew members. Thanks to a number of absurd assumptions concerning the Lunar Environment, with regards to the braking angle and soft-landing delta-v requirement, the mass of the LK very quickly rose and the battle to reduce it again began in earnest. And on top of the Mass Budget itself, there was also the mass distribution of the LK to consider. It was determined that they could, at best, have the cabin centre of mass 30mm off the thrust axis otherwise stable flight of the LK would be impossible. These twin considerations of mass and mass distribution would constitute the primary engineering challenges of the LK throughout its development.

By the time advanced design work was completed, in the Winter of 1962, most of the LK design issues had been rectified, if only on paper. Still, Yangel a multitude of engineering challenges. While a cabin atmosphere of 100% O2 at 0.4 Bar had been considered, but such an environment would require the use of special armatures and fire-proof materials that could cope with a near doubling of the normal O2 levels. Adding in the concerns with Cosmonaut Safety and the idea was rejected in favour of a 0.74 Bar O2/N2 Mix which was deemed far more suitable from a crew safety point of view. The obvious penalty for the greater cabin atmosphere pressure was a need to double the cabin structure mass, which was forced to be extracted, in part, from the deletion of the second crew member and thus making the LK a single-man spacecraft, at least for the initial run.

To add to the problems facing it, Soviet experience in manual spacecraft control was limited at the time of LK development, and they were required to go right back to the first principles to determine the control layout and cosmonaut position, who in turn needed an elaborate system of tie-down braces and strips to keep him on the centre of mass in order to maintain control of the LK during flight and manoeuvres.

Even the engine development was tricky. With the chosen design forcing a need for the engine to be restarted after it landed the LK on the Lunar Surface along with a deep throttling range to enable a safe and controlled landing. This demanded new materials and mechanical solutions to develop a safe, reliable, and durable engine with restart capability. Along with the main engine, it would also feature a twin-chambered reserve engine that could back-up the main engine should it fail. This was seen as necessary since the engines were to be pump-fed and needed to be fired twice for its mission.

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RD-858 Engine plus back-up for the LK Lander

Even so, by the beginning of 1968, just over five years after actual work on it began, the LK Lander was ready for its first test flight. Launched atop a specially adapted R-7 Launch Vehicle, this first test was to prove the capabilities of the LK within the confines of LEO. The R-7 functioned well and less than 10 minutes later, the LK was in Orbit.

After three-and-a-half days in Orbit, simulating the coast phase from LEO to LLO, the RD-858 engine was ignited, imitating the final descent to the Lunar Surface following Block D separation, pushing the LK Apogee to over 1,200 Km. After another 4 days in its new orbit, simulating the maximum possible surface stay time of what even a modified LK could hope to achieve, a second burn of the LK engine was conducted, proving the engine in a Lunar Surface to LLO manoeuvre, and making the new Apogee a shade over 14,000 Km. Following these tests, further small manoeuvring burns and adjustments were made to replicate the rendezvous and docking procedure with an orbiting Soyuz 7K-LOK.

Initially referred to as Cosmos-379, it was only following the tests, to which the LK had performed without major incident, that the Soviet Government revealed to the World the true purpose of the unmanned flight, announcing the successful test of the LK Lunar Lander that would take a Soviet Cosmonaut to the Lunar Surface and back.
 
There will be a lot of bad surprise for NASA coming
the second Test flight of Saturn V aka Apollo 6, here it show it ugly site:
severe pogo oscillations by F-1 engine for 30 second, damage the LM simulator.
two J-2 engine of second stage had be shut down after they show problem and the S-IVB J-2 engine failed to restart.

The F-1 engine support meant that when the inboard engine was cut out early (to prevent excessive acceleration), it would cause it to bounce a bit, which affected the propellant flow to the still-running engines, which (mainly) caused the POGO.

As for the J-2 engines, the flexible pipes they used for the early Saturn V's hadn't factored in the additional dampening they got from moist air freezing around them, and when one of them broke, the signal to shut it down went to the wrong engine since they got the wires crossed.


The LM is not ready for flight, what make Apollo 8 flight useless, why copy the soviets ?

They've only gone circumlunar at this point, they haven't gone Orbital, NASA still has a chance here.


On N1 block A problem, it's seem that shut down engine Turbo-pumps, produce hell of vibration during running dry.
And that complex pipework is very vulnerable for this Pogo.

Those pipes are a major point of concern, but it's something they just have to deal with, and try to rectify as they debug the whole thing.
 
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Thx for explanation on Apollo 6 failures

They've only gone circumlunar at this point, they haven't gone Orbital, NASA still has a chance here.
that true make first Lunar orbit as second is chance, i hope they got no Apoloo 13 problem on way to moon...


Those pipes are a major point of concern, but it's something they just have to deal with, and try to rectify as they debug the whole thing.

for those who not understand
the Saturn 5xF-1 engine get there fuel from from above by tubes
the N1 24xNK-15 engine get there fuel almost horizontal by tubes

this picture give a rough view of plumbing problem on N1
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Probably the pressure on Grumman at this point is huge. They are behind schedule on the LM and I don't see them being able to move any faster. You do have LM 1 flying on January 68 as Apollo 5 in a un-manned test. However they are over a year away for a manned test flight of LM 3. This is where mistakes can happen as with the Block 1 Command Module.
 
Probably the pressure on Grumman at this point is huge. They are behind schedule on the LM and I don't see them being able to move any faster. You do have LM 1 flying on January 68 as Apollo 5 in a un-manned test. However they are over a year away for a manned test flight of LM 3. This is where mistakes can happen as with the Block 1 Command Module.

That's pretty much it. And the situation isn't being helped by the fact that since the USSR is only announcing their successes, the US is having to play a guessing game as to just what sort of progress they're making.

All NASA really knows for now - thanks to reports via the CIA and what the Soviet Press reveals - is that the Soviets have a Saturn-sized LV, have their Lander in the LEO test stage, have managed circumlunar missions, and may have their Lunar Orbiter. What they don't know for sure, is just how far along they are, or what particular mission profile they're using.

Which places an enormous pressure on Grumman to get their LEM into service, adding onto that the Apollo 1 disaster - which would still be extremely fresh on people's minds - and it's clear that there's no easy solution.
 
That's pretty much it. And the situation isn't being helped by the fact that since the USSR is only announcing their successes, the US is having to play a guessing game as to just what sort of progress they're making.

Is NASA getting more funding ITTL? The only thing the U.S. can really do now is throw more money after the problem, which I don't think will help at all.

I'm guessing people in the USA are probably saying ITTL there's both a "tech gap" and an "education gap" in comparison with the USSR.
 
Is NASA getting more funding ITTL? The only thing the U.S. can really do now is throw more money after the problem, which I don't think will help at all.

I'm guessing people in the USA are probably saying ITTL there's both a "tech gap" and an "education gap" in comparison with the USSR.

the irony in 1967 Capitol hill complains about high cost of Space Program
and refused the NASA proposed 1968 budget (include Apollo application program and Voyager mars probes and Grand tour prototypes)
while Johnson order the production stop of Saturn IB and V.
in protest Administrator Webb quit his job…

Now with Soviets first around the moon and there lunar landing close by.
Capitol hill will panic and open the money bag in hope to speed things up.
and look for alternative in case the Soviets are first on moon !

under this scenario, Johnson not stop the Saturn IB and V production and ask polite for Webb to stay in his Job.
of corse Voyager mars probes and Grand tour prototypes will still be victim of budget cuts, in favor for Apollo and it's application program
 
the irony in 1967 Capitol hill complains about high cost of Space Program
and refused the NASA proposed 1968 budget (include Apollo application program and Voyager mars probes and Grand tour prototypes)
while Johnson order the production stop of Saturn IB and V.
in protest Administrator Webb quit his job…

Now with Soviets first around the moon and there lunar landing close by.
Capitol hill will panic and open the money bag in hope to speed things up.
and look for alternative in case the Soviets are first on moon!

And NASA is going about as fast as they are able to, unless they want to play fast-and-loose with the risks.


under this scenario, Johnson not stop the Saturn IB and V production and ask polite for Webb to stay in his Job.
of corse Voyager mars probes and Grand tour prototypes will still be victim of budget cuts, in favor for Apollo and it's application program

At this point, the most likely scenario IMHO is a suspension of Saturn IB/V production, with the ability to restart it quickly.

IIRC, the J2-S was ready by 1969, but the Saturn Production cancellation meant it had nothing to be used on. The F-1A I'm not so sure on, but I think it was being studied and possibly developed in the late-60's. So I believe they'd be looking into utilising those engines in the event of a restart/no suspension of Saturn production.
 
They made test ingintion of F-1A during 1960s.
had the program not stop, the F-1A would be ready in 1970. it feature was it could throttle the thrust !

The F-1A and J-2S had simplified the Saturn V production with cost reduction, with more Payload.

and what about SA-516 and SA-517 ? they were almost complete as came the order to stop Saturn V production.
after that they were cut up with welding torches...
 
And NASA is going about as fast as they are able to, unless they want to play fast-and-loose with the risks.




At this point, the most likely scenario IMHO is a suspension of Saturn IB/V production, with the ability to restart it quickly.

IIRC, the J2-S was ready by 1969, but the Saturn Production cancellation meant it had nothing to be used on. The F-1A I'm not so sure on, but I think it was being studied and possibly developed in the late-60's. So I believe they'd be looking into utilising those engines in the event of a restart/no suspension of Saturn production.

Why would the Saturn IB/V production be suspended? Are we assuming that if the Soviets get to the Moon first that the US folds it's tent and withdraws from the space race?
 
Why would the Saturn IB/V production be suspended? Are we assuming that if the Soviets get to the Moon first that the US folds it's tent and withdraws from the space race?

From what I've been reading up on since, IOTL, it was the second run of Saturn V's that was cancelled following the initial 15 that were built in the first run.

The second proposed run appeared to have the engines uprated to increase the Saturn V performance and may have seen stage stretching - although that second point looks unlikely given the restrictions imposed by the VAB doors.

In short, there's still a number of unknowns that will impact on the final outcome.
 
The Soviet Union was confident and eager to reinforce their position in the Space Race by launching even more L-1 missions before the Americans had a chance to catch up.

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The beginning of the spaceflight year was marked by the L1-2 spaceflight. Multiple technical delays (mostly involving the re-entry guidance systems) pushed it beyond January until finally on February 12th it's N11 launch vehicle successfully lifted off from Baikonur Cosmodrome. Valeri Bykovsky (commander) and Nikolai Rukavishnikov (flight engineer) piloted the second lunar flight and where entirely qualified to do so. Mission backup Pyotr Kilmuk attempted it "bump" Bykovsky from the mission but was unsuccessful in his attempts. The mission was heavily buffeted by safety margins and performed even better than previously. The L1-2 mission augmented the Luna Orbiters in searching for the best lunar landing candidate sites. Spending another day in the vicinity of the Moon allowed detailed mapping of the Moon's gravity field along with countless colour photos and film footage of the it's surface. After another weeklong spaceflight the crew finally landed just 24 km from it's target Soviet recovery ship the Taman. The USSR was now finally gaining experience with ocean landings. This was Bykovsky's first spaceflight since the 1963 Vostok 5 mission and the last of his career.

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The L1-3 mission was also piloted by a veteran Vostok pilot. Pavel Popovich had piloted the Vostok 4 mission back in 1962 and was eager to fly again (especially considering it's to Moon). His flight engineer Vitali Sevastiyanov was a rookie with his entire spaceflight career ahead of him, but it would start around the Moon. The mission achieved the closest approach to the Moon of any of the L1 missions (coming within just 102 km of it's surface). Their successful recovery on April 9th 1968 brought about the end of the L1 circumlunar program. More missions could occur if the L3 program was significantly delayed but either way the L1 was insufficient for the future of the Space Race. The L1 was incapable of performing of performing Lunar Orbital flights and was therefore an evolutionary dead end.

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The Soyuz 7K-LOK was the solution to this dilemma. Composed primarily of a modified Soyuz 7K-OK the spacecraft used a Block D upper stage to break itself into and out of Low Lunar Orbit. This meant that the Soyuz 7K-LOK could rendezvous with the LK lander in lunar orbit and potentially beat Apollo to the lunar surface. While the Soyuz 7K-OK had flown previously both manned and unmanned on several successful flights the modified variant had never flown (breaking the R-7's meagre mass budget) and never in the configuration it would on a lunar flight (which included the Block D).

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This all changed on August 22nd when the unmanned Soyuz 7K-LOK performed its first round of orbital testing. Launched on an N11 rocket in its lunar orbital configuration (Block D and all) the spacecraft performed numerous test firings of the Block D. This was designed to simulate breaking into and out of Low Lunar Orbit as well as the Soyuz making course corrections in Cis-lunar space. After three days in LEO (simulating a lunar transit it fired its Block D's engines reaching an initial apogee of 7210 km while the simulating the Lunar Orbit insertion burn. After about 24 hours (simulating it's time in lunar orbit) the spacecraft fired it's Block D engines again and ascended to a highly elliptical 14,035 km orbit to simulate the Trans Earth Injection Burn. Like in the L1 missions the descent module was tested via re-entry. With the manoeuvring and engine firing occurring perfectly as planned no major malfunctions and the entire biological payload still alive the engineers considered it a complete success. Designated Cosmos 211 the mission proved that the Soyuz-LOK was capable of supporting a crew and braking them into and out of LEO.

However the USSR was not aiming for mere lunar orbital mission they wanted to land and to do that would require perfecting rendezvous and docking with the LK. So on June 7th the crews of Soyuz-5 and Soyuz-6 lifted off less than 24 hours apart from one another. In another stunning spaceflight victory both spacecraft were crewed by three cosmonauts (breaking Gemini 6A and 7's population in space record). It was the first time six people were in space at once. After four failed attempts over the course of four days the two spacecraft finally found each other and linked up. The docking time had now been cut from one week to three days but the crews still had a chance to perform a televised EVA crew exchange and various experiments. "The Six Man Space Complex" was highly publicised as the Soviet Press emphasized it was four times larger than any American spacecraft (referring only to the launch Gemini). But they would not stop there. With their newfound rendezvous and docking experience the Soviets would attempt an even more ambitious Soyuz mission.

The Soyuz 7 mission was another ordinary Soyuz 7K-OK but it had a much more extraordinary target than another mere Soyuz, the LK lander itself. The R-7 was launched four days prior to the launch of Soyuz 7 mainly to simulate the time it would take it to reach lunar orbit. Soyuz 7 also spent another four days just circling the Earth simulating the time it would take them to reach Lunar Orbit. While the Soyuz as the dominant target the LK was passive. After a successful docking Vladimir Shatolov performed an EVA to transfer himself into the LK. Earlier in the mission the crew tunnel had also allowed him to successfully enter the spacecraft, thus both the main access point and it's backup were tested. After a short period of manoeuvring nearby Soyuz 7 Shatolov re-docked with the Soyuz and promptly returned to his colleagues. While they returned the LK performed various unmanned tests and engines burns before being left dead in a decaying orbit when it's testing career was finish.

The planned penultimate Soviet Spaceflight of the year would combine all their previous testing in one single mission. First the LK/Block D combo reached orbit by virtue of the N11 and following a single simulating Lunar orbit insertion burn the manned Soyuz sn/7 was launched by it's own N11. For the first time the Soyuz 7K-LOK configuration, complete with it's Block D, was now manned by cosmonauts. After another four days with the LOK performing it's own insertion burn the two were docked together in a Medium Earth Orbit. After another crew transfer (by both means) the LK was once again dancing to the whims of the pilot onboard. After six hours of life support testing the two re-docked, earth looming large in the background before returning to Earth in a simulated TEI burn. With five dockings ,two manned LK tests, one LOK test, seven Soyuz-OK tests, three L1 tests and countless N11 launches the Soviets were confident they were ready in all respects for a Manned Lunar N1-L3 flighy, all that is, except for the N1 itself.

The wakeup call to NASA that the USSR was not far from performing lunar orbital/landing missions, was startling as they hadn't performed a single manned LEO Apollo flight, let alone manned LM test, circumlunar, lunar orbital or landing mission.

The secrecy of the Soviet Space Program and their refusal to announce failures, errors or mistakes meant the US had no idea how far along they were. It was fairly certain that the USSR, at least for the moment was in the lead. Though hopefully, that was soon to change.
 
Why would the Saturn IB/V production be suspended? Are we assuming that if the Soviets get to the Moon first that the US folds it's tent and withdraws from the space race?

in our time line Johnson ended the Saturn IB/V production for several reason:

the CIA gave precise information about the actual state of Soviet Space program, there were far behind schedule
the Vietnam war devoured billion dollars, needed elsewhere
the NASA 1966 budget reach it maximum of 5,933 billon or 4.41% of Fed Budget ! ( today would be 33,514 billon dollar)
and in 1967 NASA demand even a 5,100 billion 1968 budget, capitol Hill went ballistic, they approved only 4,588 billion Dollar
and Johnson needed money for his social program.


in Red Star Time line things could look much diverent:
the CIA screams "The SOVIET LAND ON MOON SOON!"
the Vietnam war devoured billion dollars, needed elsewhere, while Johnson need a moral boost for USA.
also here NASA will make there demand for a 5,100 billion 1968 budget, what capitol Hill approved under condition: priority on Apollo program and no Voyager/Grand tour.
SA-516 & 517 are complete as reserve in case the SA-502 problem hit another Saturn V, then mothballs the production line.
 
From what I've been reading up on since, IOTL, it was the second run of Saturn V's that was cancelled following the initial 15 that were built in the first run.

The second proposed run appeared to have the engines uprated to increase the Saturn V performance and may have seen stage stretching - although that second point looks unlikely given the restrictions imposed by the VAB doors.

In short, there's still a number of unknowns that will impact on the final outcome.

Looking over some figures. The VAB doors where 456 feet hight. The Saturn V tower was 380 feet high with the rocket 363 feet high. The Mobile Launch platform was 24 feet high and the Crawler Transporter was 20 feet high so everything was 424 feet high. This gives around 20-30 feet of more height capability on the tower. It isn't much but it does allow some increases in height of the rocket. The other way to increase Saturn V payload without a significant increase in height is to use Solid boosters. That isn't without using other measures like a tower crane on the roof of the VAB. You assemble most of the stack in-doors and you move it outside to assemble the final parts.
 
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