Construction

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

Motor mount assembly be easy and straight forward. Well, shiver me timbers, blow me down! Blimey! I am nay a fan o' t' Estes shock cord mount method.  Therefore, when buildin' t' motor mount, I tied Keelhaul®©™ Cord (150lb) around t' motor tube and under t' motor hook. Slipped it through t' notch in t' centerin' rin' and glued t' knot and cord t' t' mount. Ya scallywag!   Post build I will attach t' kevlar cord t' t' elastic shock cord. Blimey! Blimey!  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. Well, blow me down!   I used watered down Elmer's wood filler t' seal t' fins. Well, blow me down!   Gluin' on t' fins was straight forward. Arrr!  I used t' Estes fin alignment jig.  It's nay a perfect jig, especially with these larger/bigger fins, me bucko, but it helped get t' job done. Aye aye! Blimey!   I applied multiple layers o' wood glue for fillets. Blimey! Ya scallywag!  I was nay happy with t' way t' fillets looked, arrr, matey, nor their size/shape.  I then used a little bit o' BSI long-cure epoxy t' enhance t' fillets. Begad!  A metal rod be used t' drag and smooth out t' fillets. Begad! Blimey! Wiped t' rod off after each drag. Ahoy! Process be repeated several times for t' desired effect. Well, blow me down! Aye aye!  

I then glued in t' motor mount. Begad! Aye aye!  Used a dowel t' rub some glue on t' inside o' t' tube and slid it halfway in. Ya scallywag! Ya scallywag!  I then put in more glue for t' aft rin' and slid it in t' rest o' way. Avast, me proud beauty!  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. Ahoy! Durin' this process t' kevlar cord was pushed out through t' motor mount so it was out o' t' way.  

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