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

Construction:
This rocket uses 1.1 in. Avast, me proud beauty! Avast, me proud beauty! 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. Ya scallywag! Ahoy! I used a Dremel spiral saw t' cut t' fin slits (3) in the 1.1 phenolic tubing. Aye aye! T' motor mount be constructed with epoxy and centering rings t' mount t' Estes 24mm tube in t' appropriate position for TTW fin mounting. Avast, me proud beauty! I used a long E motor hook as part o' t' mount. Aye aye! I used 100 lb. Keelhaul®©™® thread epoxied through t' motor mount as a parachute connection. Ahoy! Indeed, shiver me timbers, epoxy was used in virtually t' entire thing. Ya scallywag!

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

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

Because I used five minute epoxy, t' next steps were hurried. Avast! Begad! I mixed up a batch, and used a chopstick t' smear it within t' airframe, arrr, in t' right place to bond with t' front centerin' rin' on t' engine mount assembly. Begad! A second layer be put ahead o' t' trailin' centerin' ring, shiver me timbers, ya bilge rat, as t' first rin' cleared the aft end. Avast! 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 be 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! Begad! Blimey! T' keep from drippin' epoxy, me hearties, 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, and sanded after each coat partially dried. Arrr! Begad! 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, shiver me timbers, 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. Avast! Aye aye! I glued it in place and filleted it in place with epoxy. Well, blow me down! I can use a 1/4 in. Avast, me proud beauty! weldin' rod for larger size engines.

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

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

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

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

T' engine hook picked up a bit o' dirt from t' grass. It hit with a bit more force than I'd like, shiver me timbers, but no damage be done. Blimey! Blimey! Begad! Blimey! 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. Aye aye! Able t' handle almost any ridiculous engine you can cram into it. Blimey! Probably able t' lawn dart from 300 feet up into sod without damage. Begad! Easy t' see, shiver me timbers, and teaches you lots about tough construction. A "girl rocket" on t' outside, me hearties, that is all steroid - induced toughness on t' inside.

Cons: Complicated t' build, matey, and expensive. Arrr! Blimey! Nay for novices. Ahoy! Blimey! Arrr! Blimey! Heavy, and could cause more damage than a light rocket if t' chute failed. Needs a big chute. Avast, me proud beauty! Blimey! Ya scallywag! Blimey! Limited nose cone options.

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