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I suggest using the Mk1 inline cockpit with either a nose tank or a aeroshell cone for better heat resistance.
edit: i made a quick video how to do it the easy way, still converting i link it here after upload...
http://steamcommunity.com/sharedfiles/filedetails/?id=803282922
Could you share that craft? I want to test it in my game and see if it as the same issue as my other Mk1 ships. If it does then I know its a problem with my game.
place it in "...\Kerbal Space Program\saves\your profile\Ships\SPH
edit: i forgot to add the reactionwheel to the craft, maybee add it. the craft is no spaceplane so you have to cheat it to orbit, i just did a quick reentry for testing purpose. add the tank on top like in the video to decrease orbit..
do you use mods in your game? outdated mods can cause weird results so i suggest to start a fresh game and add just mods updated to last game version...
Yes I use mods, but only ones 1.2.1 compatible. And only a few designed for extra content like the OPT spaceplanes mod.
Funnily enough my mk2 spaceplane can manage a 3000m/s re-entry from a return to LKO manouver. I dont need to re-orbit, I can just drop right in to the atmosphere and hit the brakes. My Mk1's can barely enter at all from 2000ms/ 70k de-orbit burns.
pretends on the craft, drag begins at 70k so you always can use it to slow down, optimal reentry speed is about 1800m/s to 1600m/s. works with jets and rockets i never use heatshields for reentrys from LKO. as i told in the video start from 75km orbit (~2200m/s)
and slow it down, dont use airbrakes just let the craft glide until its save. reentry above 3000m/s is suicide without heatshields lol...
if your position is 90° infront of the KSC burn retrogarde until periapsis reaches 0km,
your height above the KSC should then be near 40km. (switch to atmospheric flight)
the whole reentry process starts at 70km cause you have already atmospheric drag here,
you have to do some aerobraking at height between 70km (reentrystart) to 50km (reentry end),
you can notice the red glow of your craft here, stress and heat caused by drag.
between 70km and 50km you should slow down to 1600-1800m/s
(for safe reentry without heatshield)
if you start the whole process from 100km orbit your speed is near 2300m/s between 70km and 50km so then you maybee need a heatshield...
sorry mate english is not my native language so i hope i made it clear now...
sheet: http://www.hq.nasa.gov/pao/History/SP-4209/p68.jpg
watch the video i linked, i think we made mistakes of comunication here :|
reentry with small crafts mk1 etc:
https://youtu.be/2x7XyvTikuY?t=146
and the reentry trajectory of my space shuttle to compare:
https://youtu.be/nMDy5HckCVw?t=229
i call the second one "hotdrop" cause the craft come in with high speeds at a steep angle but it works with mk3 either, you need a well balanced craft to do that and i dont suggest to try it with mk1...
i need to learn better english i guess :D