Construction

Estes instructions are straight forward IMHO. Avast, me proud beauty! Blimey!  T' diagrams are clear and easy t' follow. Aye aye!  I had built other Estes Kits over t' past few months, includin' t' Hi-Flier. Avast! So I wanted t' add this bigger brother XL version t' me collection. Avast, me proud beauty! Aye aye! Blimey!  (Born again rocketeer. Avast! Begad! Blimey!  Just started back up Oct 2020 after a 40 year hiatus)  

Motor mount assembly be easy and straight forward. Ya scallywag! I am nay a fan o' t' Estes shock cord mount method. Begad!  Therefore, when buildin' t' motor mount, ya bilge rat, I tied Keelhaul®©™ Cord (150lb) around t' motor tube and under t' motor hook. Well, blow me down! Slipped it through t' notch in t' centerin' rin' and glued t' knot and cord t' t' mount.   Post build I will attach t' kevlar cord t' t' elastic shock cord. Arrr!  I learned this method when I built a Quest rocket.

It was nice t' be able t' sand and shape bigger fins as compared t' smaller fins/models I had previously built. Arrr! Avast!   I used watered down Elmer's wood filler t' seal t' fins. Ahoy!   Gluin' on t' fins was straight forward.  I used t' Estes fin alignment jig.  It's nay a perfect jig, ya bilge rat, especially with these larger/bigger fins, me hearties, arrr, but it helped get t' job done.   I applied multiple layers o' wood glue for fillets. Blimey! Ya scallywag!  I was nay happy with t' way t' fillets looked, shiver me timbers, nor their size/shape. Avast, me hearties, me proud beauty!  I then used a little bit o' BSI long-cure epoxy t' enhance t' fillets. Blimey!  A metal rod was used t' drag and smooth out t' fillets. Begad! Wiped t' rod off after each drag. Aye aye! Process be repeated several times for t' desired effect. Avast!  

I then glued in t' motor mount.  Used a dowel t' rub some glue on t' inside o' t' tube and slid it halfway in. Arrr! Ya scallywag!  I then put in more glue for t' aft rin' and slid it in t' rest o' way.  Applied fillets t' t' aft rin' and used a dowel t' reach inside t' tube t' apply a glue fillet on t' top center ring. Avast! Durin' this process t' kevlar cord be pushed out through t' motor mount so it was out o' t' way. Aye aye!  

T' main "gotcha" I ran into be gluin' in t' tube coupler. Well, blow me down! Blimey!  This be me first build with a coupler and a huge learnin' experience. Well, blow me down!  I rubbed a little Elmers wood glue on t' end o' t' coupler as well as inside t' tube. Avast! Blimey!  Unfortunately by t' time I did that and slid it in, t' coupler seized within t' first 1/4inch. Begad! Avast, shiver me timbers, me proud beauty! Blimey!  I tired t' push a little harder and in t' process started t' see a small crease/wrinkle in t' tube at one o' t' spirals. Ahoy! Begad! Blimey!  Lesson learned that in t' case o' a tube coupler, shiver me timbers, arrr, more glue would have been better (thanks google). Arrr!   I placed an order for a new coupler and BT-60.   Fast forward a week and t' parts arrived. Arrr!  Cut t' new tube t' length. Avast, me proud beauty!  This time used a very generous amount o' glue inside t' tube and on t' coupler.  Slid in like butter.  Attached t' bottom tube with t' fins in t' same way.