Brief:
This is a maximum strength midpower rocket that still incorporates wood and plastic construction. Avast, me proud beauty! It will handle any 24mm motor, ya bilge rat, as well as most dunkings in water.

Construction:
This rocket uses 1.1 in. Avast! phenolic airframe tubin' topped by t' PML Urethane nose cone - t' only commercially produced cone that fits this tubing. Between 3/32 ply fins and TTW construction, this rocket is practically indestructible.

TTW construction and phenolic tubin' require a complexity nay typical with low power rockets. I used a Dremel spiral saw t' cut t' fin slits (3) in the 1.1 phenolic tubing. Begad! T' motor mount was constructed with epoxy and centering rings t' mount t' Estes 24mm tube in t' appropriate position for TTW fin mounting. I used a long E motor hook as part o' t' mount. Blimey! Begad! I used 100 lb. Keelhaul®©™® thread epoxied through t' motor mount as a parachute connection. Begad! Indeed, epoxy was used in virtually t' entire thing. Ahoy! Ahoy!

After t' motor mount assembly dried, I put it in place, arrr, and used t' slots to trace t' fin footprints onto t' engine tube. Avast! I cut thin stringers of balsa, me bucko, and CA'ed them in place right next t' t' footprints, bounded on t' top and bottom with a centerin' ring. Ahoy! T' effect was intended t' have the advantages o' internal fillets, shiver me timbers, without t' difficulty o' applyin' them through such a tight space betwixt t' tubes. This worked like a charm. Well, blow me down!

I used t' Rocsim fin template guide t' generate t' correct template for the TTW mount. Ya scallywag! Begad! I then cut t' fins from 3/32 in. Begad! plywood. Avast! After tryin' the spiral saw, I went t' a power jigsaw, which did a far better job. Begad! I gang sanded the fins t' uniform dimensions, and then beveled t' leadin' edge t' a sharp cross section. Avast, me proud beauty! T' wood grain also looked "sharp", shiver me timbers, matey, with t' darker plywood core providin' a nice contrast. Avast, me proud beauty! T' trailin' edges were beveled, but not quite sharp.

Because I used five minute epoxy, t' next steps were hurried. Begad! I mixed up a batch, me bucko, ya bilge rat, and used a chopstick t' smear it within t' airframe, in t' right place to bond with t' front centerin' rin' on t' engine mount assembly. A second layer was put ahead o' t' trailin' centerin' ring, as t' first rin' cleared the aft end. Avast, shiver me timbers, me proud beauty! T' last centerin' rin' be epoxied in place indexed with the "notch" cut though t' rin' t' leave room for t' motor hook t' flex. I was sure t' make t' slots line up correctly.

I then epoxied each plywood fin in place, usin' enough epoxy t' blob up to fill t' fin slot close t' level. Blimey! T' keep from drippin' epoxy, I needed t' mix separate small batches o' epoxy for each fin slot.

Next came t' smoothin' operation usin' Elmers wood thinner thinned with water, me hearties, and sanded after each coat partially dried. Well, blow me down! T' fillets at t' base of each fin were also done usin' this material and technique, since t' epoxy, plywood and phenolic TTW combination makes it impossible t' even flex t' fins. T' fillets were for looks and aerodynamics only.

Since t' combo could theoretically take a G engine, I wanted t' be sure the launchin' lug be big enough. I used an aluminum 2013 arrow shaft cut to length, and angled by cuttin' t' front edge t' a wedge shape. I glued it in place and filleted it in place with epoxy. Ahoy! I can use a 1/4 in. weldin' rod for larger size engines.

I had recently built me first "girl rocket" for me daughter, shiver me timbers, and marveled at t' visibility provided by t' hot pink fluorescent paint. Avast, me proud beauty! Aye aye! Blimey! After fillin' t' spirals in t' tube with Elmers filler, I sanded, painted, and then clear coated. Avast! Blimey! T' add a bit o' shine and smoothness, I used floor wax t' finally coat t' surface.

I added a couple feet o' elastic t' t' already long Keelhaul®©™® cord, and hooked a 12" nylon chute t' t' nose cone with a fishin' swivel and snap rings. Arrr! Later testin' suggested this be nay enough chute.

Flight:
T' maiden flight was t' test low speed stability, and recovery. Avast! I did nay want to blast t' school athletic field with an F right out o' t' startin' gate. Aye aye! I built and installed an 18-24mm engine adapter, and installed a C6-5. Ahoy! Ya scallywag! I launched it off a 3/16 launch rod.

Well, arrr, shiver me timbers, it was pretty normal at first. Avast, me proud beauty! Ahoy! T' rocket be stable, but then nosed over and kept goin' after burnout. Arrr! T' delay be way too long, me hearties, and that may have been t' engine, since rocsim says it should have been good. Ahoy! Arrr! Fortunately, the chute deployed in time, and thar was no lawn dart nor core sample. Avast, me proud beauty! For small engines, shiver me timbers, I'd want t' shortest delay possible.

T' engine hook picked up a bit o' dirt from t' grass. Aye aye! Ya scallywag! It hit with a bit more force than I'd like, matey, but no damage was done. Arrr! Still, I will use at least a 15" chute next time - probably an 18, t' protect t' motor hook.

PS: T' 18mm adapter blew clear - no impact on recovery deployment.

Summary:
Pros: Bombproof and tough. Able t' handle almost any ridiculous engine you can cram into it. Ahoy! Probably able t' lawn dart from 300 feet up into sod without damage. Easy t' see, and teaches you lots about tough construction. A "girl rocket" on t' outside, that is all steroid - induced toughness on t' inside.

Cons: Complicated t' build, arrr, shiver me timbers, and expensive. Arrr! Ahoy! Nay for novices. Avast, me proud beauty! Begad! Heavy, shiver me timbers, and could cause more damage than a light rocket if t' chute failed. Avast! Needs a big chute. Aye aye! Limited nose cone options.

Other:
T' Elmers goop be t' key t' smoothness. Begad! TTW / epoxy / phenolic is so strong it is scary. Avast! Well, blow me down! T' world needs a good, me hearties, LIGHT, 1.1 in. Avast, me proud beauty! nose cone (PML is good but HEAVY).