At the moment we have a grand total of 36 boys who have picked-up their kits. We have already bought enough rubber bands to give them each 3 brand-new bands for competition day, and we have stressed to use them sparingly (use the kit bands for testing). I did a bunch of testing last evening, and found that as long as we lubricate the bands before racing we're getting 10 runs on our test rockets before we start running into band breakage (usually due to defects identified beforehand, which can be avoided).
As far as winding...we have that taken care of too (as one of the online complaints was that the boys get tired of winding their rockets). I built a 4-position drill-powered winder, with an electronic counter for about $50. We're going to put 150 turns on all the rockets, and then let the boys wind them more or less from there. Brewmeister, we're actually using what I'd describe as "double-handled slalom ski rope"....completely home-brewed to hold the dowel, and hook onto the drill winder.
Also with our latest testing, I've found that installing & balancing the prop is going to be "key" with these things. I did that with our most consistent "rocket" tester, and it consistently runs the full 40' length of the track. We went ahead and balanced the rest of the props, and now all the designs (including the bricks) are consistently hitting the 40' mark.
We were noticing that when the rockets were initially taking-off, the ones that "vibrated" the most, were traveling the least distance. Sometimes releasing them "just right" would produce a good run...but then the next run would be pathetic.
As far as running the races...we're definitely leaning toward running "race as ready" format. I'm just trying to figure-out if the Grand Prix Race Manager software can be configured in that format. I've been concentrating on getting the track and timing circuits working properly together, over how to actually run the races. Now that we have some time to step back and evaluate, this is definitely the next thing we're going to look at.
Thanks for all the suggestions everyone, please keep them coming...it is a BIG help. :-D