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A cabin fire during a launch pad test on January 27 at Launch Pad 34 at Cape Canaveral killed all three crew members-Command Pilot Virgil I. "Gus" Grissom, Senior Pilot Edward H. White II and Pilot Roger B. Chaffee. Immediately after the fire, NASA convened the Apollo 204 Accident Review Board to determine the cause of the fire. Although the ignition source was never conclusively identified, the astronauts' deaths were attributed to a wide range of lethal design and construction flaws in the early Apollo Command Module. The manned phase of the project was delayed for 20 months while these problems were corrected.

The launch simulation on January 27, 1967, was a "plugs-out" test to determine whether the spacecraft would operate nominally on (simulated) internal power while detached from all cables and umbilicals. Passing this test was essential to making the February 21 launch date. The test was considered non-hazardous because neither the launch vehicle nor the spacecraft was loaded with fuel or cryogenics, and all pyrotechnic systems were disabled.

At 1:00 pm EST (1800 GMT) on January 27, first Grissom, then Chaffee, and White entered the Command Module fully pressure-suited, and were strapped into their seats and hooked up to the spacecraft's oxygen and communication systems. There was an immediate problem: Grissom noticed a strange odor in the air circulating through his suit which he compared to "sour buttermilk," and the simulated countdown was held at 1:20 pm, while air samples were taken. No cause of the odor could be found, and the countdown was resumed at 2:42 pm. (The accident investigation found this odor not to be related in any way to the fire.)

A voltage transient was recorded at 6:30:54 (23:30:54 GMT). Ten seconds later (at 6:31:04), after Chaffee said the word "Hey," scuffling sounds followed for three seconds before Grissom reported a fire that began that minute. Chaffee then reported, "We've got a fire in the cockpit," while White responded to Chaffee's comment. After 12 seconds, Chaffee urged the crew to get out of the Command Module. Some witnesses said they saw White on the television monitors, reaching for the inner hatch release handle as flames in the cabin spread from left to right and licked the window. The final voice transmission from the crew was very garbled. "They're fighting a bad fire-let's get out. Open 'er up" or, "We've got a bad fire-let's get out. We're burning up" or, "I'm reporting a bad fire. I'm getting out." Only 17 seconds after the first indication by crew of any fire, the transmission ended abruptly at 6:31:21 with a cry of pain and then a hiss as the cabin ruptured after rapidly expanding gases from the fire over-pressurized the Command Module to 29 psi (200 kPa) and burst the cabin interior.

The initial phase of the fire lasted only about 15 seconds before the Command Module's hull ruptured (which occurred three seconds after the final crew communication). As the cabin depressurized, the convective rush of air caused the flames to spread rapidly, beginning the second phase. The third phase began when most of the atmosphere was consumed. At this point, the fire largely stopped, but massive amounts of smoke, dust, carbon monoxide, and fumes now filled the cabin. Although the cabin lights remained lit, the ground crew was at first unable to find the astronauts through the dense smoke. As the smoke cleared they found the bodies but were not able to remove them. The fire had partly melted Grissom's and White's nylon space suits and the hoses connecting them to the life support system. Grissom had removed his restraints and was lying on the floor of the spacecraft. White's restraints were burned through, and he was found lying sideways just below the hatch. It was determined that he had tried to open the hatch per the emergency procedure, but was not able to do so against the internal pressure. Chaffee was found strapped into his right-hand seat, as procedure called for him to maintain communication until White opened the hatch. Because of the large strands of melted nylon fusing the astronauts to the cabin interior, removing them took nearly 90 minutes.

The Apollo 1 Command Module has never been on public display. After the accident, the spacecraft was removed and taken to Kennedy Space Center to facilitate the review board's disassembly in order to investigate the cause of the fire. When the investigation was complete, it was moved to the NASA Langley Research Center in Hampton, Virginia, and placed in a secured storage warehouse.

On February 17, 2007, the parts of CM-012 were moved approximately 90 feet (27 m) to a newer, environmentally controlled warehouse. Only a few weeks earlier, Gus Grissom's brother Lowell publicly suggested CM-012 be permanently entombed in the concrete remains of Launch Complex 34.

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