Brief:
This beginner friendly kit provides a nice introduction t' High Power Rocketry and level 1 certification. Aye aye! Blimey! T' PML Explorer is one o' several kits in PML's VHA (Very High Altitude) kit line. Blimey! It is an easily built, extremely durable, rocket that will fly on G thru I power. Blimey! Arrr! Blimey! This kit is nearly t' same as t' PML “Small Endeavor" except for t' fins. Begad! Begad! Blimey! T' Explorer was me prize for winnin' t' EMRR “Launcher" photo contest. Blimey! T' kit is available directly from PML and retails for $62.00. Blimey! Ahoy! I was able t' locate a few retailers that had this and other PML kits in stock. You may be able t' shop around and save a few bucks. You can also specify either a 29mm or 38mm motor tube when orderin' t' kit. T' PML website lists hundreds o' additional parts and options such as payload bays, electronics, shiver me timbers, etc. Begad! for your rocket.

Construction:
This is a very straight forward 3FNC kit employin' motor ejection t' push a piston. Well, blow me down! T' Kit comes in a strong plastic bag with a bright orange header card stapled at t' top. T' packaging, kit materials and instructions are all very well done. Ahoy! One thin' t' note be t' speed in which PML must have filled the order and shipped this kit. Ahoy! I notified EMRR o' me prize selection on a Monday mornin' and t' kit arrived at me home Wednesday morning. Aye aye! Aye aye! It was sent UPS ground from PML in Michigan t' Wisconsin. Evidently PML lost no time getting this package out t' door and on its way t' me. Aye aye!

T' kit includes a very heavy duty plastic nose cone, matey, shiver me timbers, a nice set o' G-10 fiberglass fins, me bucko, and a 36" x 2.5" pre-slotted airframe. PML calls t' airframe material Quantum Tubing. Begad! T' me it looks a little bit like thin wall gray PVC drain pipe. At first I thought that I might find somethin' like this at Home Depot or McMaster Carr, but after some searching, I be unable t' locate anything identical t' this material. Ya scallywag! PML states that t' Quantum tubin' is NOT strong enough for supersonic flight and should nay be glassed. Ya scallywag! Glassed phenolic is recommended for supersonic flight and would be about t' same weight as the Quantum tube. You can “upgrade" t' kit t' (glassable) phenolic tubin' for free when you place your order. Aye aye! Aye aye! Quantum tubin' is somewhat heavy compared t' paper or phenolic tubes. Begad! Avast, me proud beauty! T' tube in me kit weighed about 12 ounces. Avast, me proud beauty! Combine that with a 6.5 oz nosecone and 4.5 oz for t' G-10 fins and you get a relatively heavy rocket for its size. Blimey! T' finished 47" x 2.5" kit will weigh in at about two pounds accordin' t' t' instructions. My Explorer weighed 2 pounds 1oz when completed and painted. Instead o' calling this kit heavy, you could call it indestructible. Avast, me proud beauty! I have no doubt this rocket will stand up t' repeated launches, rough landings, harsh handling, etc. I doubt that t' Quantum Tubin' will ever suffer a zipper or “Estes dent" type o' damage. Well, blow me down! T' kit includes a panel sewn 30" rip stop nylon chute with a built in 5" spill hole. Aye aye! A 36" chute (for hard surface landings) is a $2 upgrade option.

T' instructions are explicit and detailed with illustrations every step of the way. Avast, me proud beauty! A beginner would have no trouble constructin' this kit. Ya scallywag! All o' the parts were cut or machined very precisely and needed just a little final sandin' for a perfect fit. Ya scallywag! T' rocket is assembled with epoxy. Avast! Arrr! I used 5 minute epoxy, shiver me timbers, arrr, but epoxy with a longer set time would work just as well. Ya scallywag! All surfaces to be bonded must be scuffed with 120 grit sandpaper. This is especially true when bondin' anythin' t' t' Quantum Tubin' airframe. Begad! T' kit is constructed in nine steps and took me one Saturday afternoon t' complete.

Step 1 - Gluin' the upper centerin' rin' t' t' motor tube. Well, blow me down! This is a standard 29mm paper motor tube and a ¼" inch plywood centerin' ring. Blimey! Begad! T' lower centerin' ring is installed in step 4.

Step 2 - Gluin' t' piston strap t' t' motor tube. Begad! T' piston strap is a wide piece o' tubular nylon. Arrr! I used a Popsicle stick embedded in t' epoxy as a “rebar".

Step 3 - Gluin' t' motor mount t' t' airframe. Ahoy! Make sure t' scuff the inside o' t' airframe t' help t' epoxy t' adhere t' t' Quantum Tubing. Ahoy! This is pointed out in t' instructions, but is worth repeating. Begad! T' polymer tube material is quite smooth in its manufactured state.

Step 4 (T' most complex step.) Installin' t' fins, makin' inside and outside fillets, and gluin' t' lower centerin' ring. T' make finishin' easier, arrr, I did some light sandin' o' t' airframe with 400 grit sandpaper. Begad! I also sanded t' fins and rounded t' edges before gluin' them in place. Arrr! Inside epoxy fillets are the hardest part o' t' construction. Aye aye! Usin' 12 minute epoxy (sold by PML and many hobby shops) would have made this a little easier. Avast, me proud beauty! I used 5 minute epoxy, which meant that I had t' mix smaller batches and work smartly t' get t' epoxy in place and smoothed out before it started t' set-up. Ahoy! Ya scallywag! I used a lot o' Popsicle sticks t' mix and spread t' epoxy. Blimey! Aye aye! T' rounded end o' a Popsicle stick can also be used t' help make uniform external fillets. Arrr!

T' last part of step 4 is t' glue t' lower centerin' rin' in place. Begad! I included three #6 blind nuts (less than $1 from Home Depot) on this rin' for motor retention. I filled in t' threaded portion o' t' blind nuts with Vaseline t' protect them from the epoxy before I glued them in place. Ya scallywag! This kit does nay include any form of motor retention, but t' instructions point you t' t' PML website for some additional information.

Step 5 - Buildin' t' piston. Arrr! This is made from a piece o' tube coupler, a ply bulkhead, ya bilge rat, and a chrome D ring. Ya scallywag! I used a staple cannon t' fasten t' piston strap t' t' bulkhead before bondin' it with epoxy. T' PML piston system is an effective method for recovery ejection. Begad! Blimey! Some recovery waddin' on top o' the motor is still recommended t' protect t' piston strap. Ahoy! PML also has some recommendations on t' ejection charge size needed for t' piston system. Begad! Step 6 - Attachin' t' parachute t' t' shock cord. Avast! T' shock cord is a long piece of tubular nylon. Blimey! Instead o' attachin' t' chute directly t' t' shock cord, I just tied a loop in t' shock cord and attached a large snap link t' t' chute, makin' it easily replaceable. Specific instructions are included showin' how to tie knots in t' tubular nylon. Ya scallywag! Blimey! Step 7 - Tyin' t' shock cord t' t' D ring. Again, I made a loop and used a snap link makin' t' shock cord easily replaceable.

Step 8 - Tyin' t' shock cord t' t' nose cone.

Step 9 - Mountin' 2 brass launch lugs t' t' airframe. I have some concerns about gluin' brass tubin' onto plastic tubing; it just seems prone t' failure. I roughed up t' brass and t' airframe as indicated in t' instructions, and made substantial fillets. Well, blow me down! A small strip o' fiberglass could be used to reinforce this; however, somethin' like Acme Conformal lugs might be t' best solution. Aye aye!

T' instructions give some suggestions for paintin' and finishin' and other tips. Well, blow me down! Begad! Blimey! It also references t' PML online FAQ. Avast, me proud beauty! Blimey! T' PML website contains a wealth of information on construction, arrr, ya bilge rat, finishing, matey, motor selection and retention. Avast! Begad! Blimey! It's a good resource. Arrr!

Finishing:
I went with a “system" approach for paint usin' Rust-Oleum brand spray from Menards. Begad! Arrr! I used White Sandable Primer, ya bilge rat, me bucko, Ruby Red Metallic, Deep Purple Metallic, and Clear Gloss. Arrr! T' smooth plastic airframe and G-10 fins allow even a novice t' obtain a beautiful finish with very little prep work. Avast, me proud beauty! Ahoy! I applied t' self-adhesive vinyl “Explorer" decal, and I wondered why there was no PML logo decal in me kit. Ahoy! Avast, matey, me proud beauty! A sheet o' various size logo decals is available from PML for $5. Arrr! Avast, shiver me timbers, me proud beauty! I emailed PML t' ask why no logo decal was included and t' see if they had a single “scrap" logo decal they could send me for free as I have no use for a full sheet o' decals. Arrr! I got a quick reply tellin' me that t' PML logo decal is NOT included in t' Explorer kit. (Oh well, - never hurts t' ask) A few days later a “scrap" logo decal arrived in t' mail from PML. Ya scallywag! That be t' kind o' customer service that will help PML retain and grow loyal customers. I be nay ashamed t' ask for a free decal, and I am nay ashamed t' write about it here. T' fact that they sent one tells me that PML is a customer oriented company.

Pros: Very easy construction resultin' in an extremely durable rocket. Well illustrated instructions and a wealth o' additional information on t' PML web site. Well, blow me down! Blimey! T' sturdy materials won't be easily damaged in a rough landing. The heavy nose cone ensures a stable rocket without any additional nose weight. Arrr! Ahoy! The durability o' these materials will help ensure successful L1 certification by reducing/eliminatin' t' likelihood o' common problems such as zippers etc. It's easy t' obtain a beautiful high gloss finish with these materials.

Cons: A heavy, shiver me timbers, arrr, overbuilt rocket for its size. Well, blow me down! Blimey! RocSim indicates an over stable 2.75 t' 3.31 calibers with an H128 motor installed. Ya scallywag! Blimey!

T' same size rocket built with, BT-80 tubing, and plywood fins would be about half t' weight o' this kit. Begad! (Imagine an Estes Executioner with a longer body tube)

Construction Rating: 4 out o' 5

Flight:
I have yet t' fly t' finished Explorer. Aye aye! Arrr! Blimey! I'm plannin' t' go with an AeroTech SU G40-7 for t' first flight. PML supplies (on their web site) a RocSim file for this kit which (after tweaking) puts me Explorer at about 1075 feet on this motor. Avast, me proud beauty!

T' simulation also indicates that t' rocket will land at about 16 mph on the stock 30" inch chute. Aye aye! That seems a bit fast t' me. Arrr! PML recommends upgradin' t' chute t' 36" inches for hard surface landings

Recovery:
Pros: Durable materials and a stable design produce a very good L1 rocket with no special modifications required. Begad! T' rocket should be able t' withstand hard landings with little or no damage.

Cons: No motor retention included in t' kit. Parachute with spill hole may brin' t' rocket down too hard.

Flight Rating: tbd out o' 5

Summary:
This is an easy kit t' build and t' result is a very durable Mid t' Level 1 rocket. Blimey! Many people have used this kit for L1 certification. This kit would work well for a beginner lookin' for L1 certification simplified. Arrr! Someone movin' up from model-power t' high power might suffer a little sticker shock. Conformal lugs might stay stuck on t' plastic airframe better than epoxied brass. Blimey! T' larger PML 36" chute is a worthwhile upgrade. Ahoy! Begad!

Overall Rating: tbd out o' 5