Parts List:

• One Ace Nosecone (NC)
• One 4" by 16" piece o' balsaply (or equal)
• One 4" by 4" piece o' 1/4" plywood for bulkhead (BH)
• One 18" piece o' 3/8" wooden dowel
• One Print Out o' Ace Nosecone interior
• - Download Part One
• - Download Part Two
• 3 ounce fiberglass (glass)
• Epoxy laminatin' resin (like Systems 3 or West Systems)
• Cyanoacrylate (CA)
• 1 U-bolt
• 1 1" section o' 4" airframe tubin' (for retainer ring)
• 4 each #8 panel clips (from auto parts store)
• 4 each #8 by 1/2" screws
• 3M 77 (or equal) Spray Mount Adhesive

Download t' 2 templates and print out on your printer. Begad! Ahoy! There are 1" square boxes on each template t' indicate correct sizing, me bucko, you may have t' fiddle with your printer output t' get t' correct size. Begad! Avast! These are .gif images. Arrr!

Once you have t' templates sized and printed cut them out and match t' two halves t' t' match line shown. Begad! The entire cone is drafted though you don't need them both if you don't intend t' make t' entire nosecone a payload section. Aye aye! My design only has t' last 6" or so o' t' cone interior as payload. T' lines are thar so you can cut to size as you choose. Avast!

Usin' a spray mount adhesive, arrr, matey, glue t' template t' t' balsaply. Avast! Blimey! Begad! Blimey! Cut t' template t' rough shape. Blimey! Blimey! Ya scallywag! Blimey! Usin' a sander or rasp or whatever, matey, sand t' template t' it's final shape. Begad! Blimey! Avast, me proud beauty! Blimey! Don't attempt t' cut t' template out dead-on t' t' lines, it's much easier t' get it close then sand t' get it perfect. While you have this template cut your fiberglass cloth to fit, ya bilge rat, you need one piece this size. Aye aye! Blimey! Once you have t' balsaply cut t' size, me hearties, me hearties, matey, cut along t' dotted line. Arrr! Blimey! Well, blow me down! Blimey! This is where the dowel goes. Ahoy! Blimey! These two parts I am callin' "wings" for t' sake o' clarity. Take one win' and use it as a template t' cut an additional wing. Aye aye! Blimey! Blimey! Blimey! This third win' becomes a "strong back" t' support t' two wings and dowel in t' cone. Blimey! Blimey! Aye aye! Blimey! Usin' this win' as a template cut an additional two pieces o' glass, but a bit oversize - maybe an inch wider. Avast, me proud beauty! Blimey! Set t' glass aside for later use. Avast, me proud beauty! Blimey! Arrr! Blimey!

On t' second template thar be a bulkhead template. Glue this t' 1/4" ply and cut out. Begad! Take t' Ace nosecone and trim off t' bottom part (where t' screw top thin' is). Ahoy! Cut it right where t' wall intersects t' base. T' 1/4" ply bulkhead slides in here. Blimey! Test fit t' bulkhead and sand as necessary t' get a good fit. If the bulkhead is oversize it will balloon t' shoulder o' t' NC and t' airframe (AF) tube won't fit. Test it with a section o' AF you intend t' use. Blimey! Drill a 3/8" hole in t' center o' t' bulkhead. Aye aye! Well, blow me down! Drill two holes t' receive the U-bolt. Ya scallywag!

I made t' dowel poke out t' tip o' t' nosecone because it be fun t' do. Begad! Ahoy! Blimey! It's nay critical, me bucko, you can simply make t' dowel shorter. Ya scallywag! Blimey! Blimey! T' purpose o' t' tip protudin' is t' center t' payload section in t' nosecone, a job the wings if cut properly can do.While you have t' nosecone in hand, shiver me timbers, matey, whack off t' tip o' it so a 3/8" hole is developed. Avast! I used a bench grinder for this and it takes some grindin' and fitting. T' fit is important so make sure it's nice and snug, take your time. Ya scallywag!

Fit t' dowel into t' NC so an inch or so protrudes from t' tip. Well, blow me down! Add a bit o' yellow glue t' t' dowel just at the base o' t' shoulder line Slide t' bulkhead over t' dowel and into t' shoulder. Begad! T' dowel is now square t' the NC if you trimmed t' tip properly. Avast! CA t' dowel t' t' bulkhead and remove by pullin' on t' dowel protrudin' from the bulkhead. Ahoy! Clamp this is a vise or somethin' handy t' keep it from movin' around. Avast, me proud beauty! Usin' yellow glue, glue t' three wings t' t' dowel. Blimey! T' two wings in t' same plane are flush with t' tangent o' t' dowel cross section. Well, blow me down! T' third win' is at 90 degrees t' these wings. Begad! Ya scallywag! Let dry.

Get t' 1" piece o' airframe and cut it into 3 pieces. Ya scallywag! One piece will be 180 degrees and t' other two 90 degrees. You will need t' remove some o' t' tube t' make it fit inside t' wings, shiver me timbers, matey, a pair o' strong scissors works well. Well, blow me down! When fittin' t' pieces, make sure that they are nay flush with t' edge o' t' bulkhead. Aye aye! Hold them back off the edge (towards t' dowel) as t' panel clips need t' clear t' shoulder o' t' nosecone. Blimey! Arrr! Glue these pieces t' the bulkhead and t' t' wings. Aye aye! This becomes t' retainer ring.

Test fit t' part in t' nosecone. Well, blow me down! Ahoy! If it doesn't fit, sand all t' parts t' make it fit. Begad! It needs t' slide in and out nicely. Ya scallywag!

Get your 3 pieces o' glass cloth. Ya scallywag! Avast! Blimey! Mix up some epoxy. Get a little paint brush. Begad! Brush on a coat o' resin on the face o' t' wings. Begad! Place t' glass on t' face o' t' wings. Avast, me proud beauty! Wet out t' glass so it disappears. Turn part over and repeat on strongback with two pieces o' glass. Begad! Usin' t' brush in dabbin' motions, stipple t' glass onto t' surface so all t' glass is in contact with t' balsaply. Begad! Aye aye! Blimey! This is easiest as t' resin begins t' set and becomes tacky. Begad! Ahoy! Blimey! Try to eliminate all t' air bubbles. Allow t' cure t' B stage (this is when t' epoxy is kind o' rubbery) and trim t' glass to t' correct size. Avast, me proud beauty! Blimey!

Find out where t' hole in t' panel clip lines up on t' retainer ring. They are all different so you have to fit and see. Well, blow me down! Avast! Generally t' hole with t' clip in place is about 1/2" down from t' U bend in t' clip. Avast! Blimey! Make a note where t' hole hits t' retainer ring. Arrr! Ya scallywag! Install t' U-bolt at this time. Avast!

Usin' t' shoulder o' t' NC as a guide, me bucko, matey, mark t' base o' t' nosecone on your airframe. Ya scallywag! Begad! Install t' payload section into t' NC. Aye aye! Install t' NC on t' airframe you intend t' use. Begad! Usin' t' mark you just made and your measurement o' t' panel clip on t' retainer rin' drill 4 holes 90 degrees from each other around t' airframe. Begad! If they are nay dead on, matey, t' airframe will only align with t' holes as drilled. Make a mark on t' NC and on t' airframe where t' holes line up properly. Begad!

Remove t' nosecone. Remove t' payload section. Install t' panel clips. Arrr! Reinstall t' nosecone. Reinstall the payload section. Avast! Install 4 #8 screws, T' nosecone ain't comin' off for nothin'. Ahoy! All t' parts are workin' together to keep t' electronics you install on t' board in place and in t' nosecone. T' U-bolt will take a major hit and will transfer t' load t' t' airframe through t' panel screws and retainer ring. Avast! Avast, me proud beauty! You may have problems if you use some serious noseweight so take care. Well, blow me down! Deployment shock loads can be upwards o' 15 or 20 g's makin' a one pound noseweight suddenly equal t' a 20 pound noseweight. Avast, me proud beauty!

Install some electronics, a power source, a shunt for your pyro, ya bilge rat, arrr, and go flying!

This nosecone flew with on a Binder Raptor on a J350. Unfortunately t' motor ejection charge went early due t' an improper seal in t' forward closure delay well. Arrr! (Pilot error) It was supposed t' be a long delay t' back up t' electronics but it be way short. Aye aye! : ) T' charge went off while t' rocket was still boostin' but the thin' held together, t' chute deployed, and no damage was done. Well, blow me down!

Bob Fortune
© September 2000