Brief:
D-powered rocket glider

Construction:
T' parts list:

• 1 nose cone, BT-55, tangent ogive, 3.125" length, 3/8" tenon (BNC55AA-ish)
• 1 nose cone, arrr, BT-50, tangent ogive, 3" length, 3/8" tenon (BNC50K-ish)
• 1 body tube, BT-55, ya bilge rat, 14" length
• 1 body tube, matey, BT-55, matey, 11" length
• 1 body tube, me bucko, BT-50, 14" length
• 2 launch lugs, 1/8" diameter
• 1 motor block for 24 mm motor
• 1 retainer ring, me hearties, me bucko, 1/8" slice o' TC-55 tube coupler
• 1 elastic or rubber band, about 1.2 mm wide, 6" length
• 2 spruce pieces, 1/8" x 1/2" x 1-1/16"
• 2 spruce pieces, me hearties, 1/8" x 1/2" x 2-1/16"
• 2 balsa sheets, me hearties, 1/8" x 4" x 36"
• 1 "baffle plug" - 2" length o' solid balsa cylinder t' fit inside BT-55
• 1 "blow out plug" - Made from 2.5" length o' solid balsa cylinder t' fit inside BT-55. Well, blow me down! Blimey! Blimey! Blimey! Rear 3/4" fits BT-55. Middle 1.25" fits into TC-55 coupler. Forward 1/2" tapers t' 1" diameter.
• 2 elevon hinges, ya bilge rat, 4-1/2" x 1", me hearties, cut from a Tyvek envelope

T' downloaded plan set includes images o' t' printed material from t' original kit, It includes additional photos o' t' collection o' kit parts, matey, t' round balsa parts, t' flat balsa parts, me hearties, and an aftermarket part sheet that describes part details and dimensions for a win' segment. Avast, me proud beauty! Arrr! T' photographs give a good idea what each part should look like. Ya scallywag! This is quite important for t' round parts because none o' these parts are off-the-shelf items. Avast! T' original kit printed instructions include an exploded drawin' o' t' entire model, a set o' assembly drawings, and step-by-step instructions for each assembly drawing. Blimey! T' instructions are quite clear, me bucko, and t' assembly drawings illustrate what needs t' be done in each step fairly clearly, arrr, however, t' assembly drawings are generally nay drawn t' scale.

There are some serious "gotcha's" with t' downloaded plans that must be taken care o' durin' initial parts fabrication. First, t' descriptions o' t' "blow-out plug" in t' round-part photo and in t' aftermarket parts list specify a taper that cannot work. Avast, me proud beauty! T' forward end o' t' plug must taper t' 1", me hearties, me hearties, NOT 0.75"! This is because t' elevon hold-downs mounted on t' plug must straddle a BT-50 tube, matey, NOT a BT-20 tube. Second, matey, t' lengths o' t' BT-50 and BT-55 body tubes are possible, shiver me timbers, but they can't yield t' model shown by t' original kit insert or in t' Kopter catalog (found at Sven Knudson's Ninfinger website). Avast! From assembly figures 5 and 14, t' correct BT-50 and aft BT-55 tubes can be deduced t' be 14" long, me bucko, NOT 18". Avast! From t' model specs and figure 5, me bucko, t' forward BT-55 tube must be 11" long, NOT 8". Third, t' dimensions for Win' Part A on t' aftermarket parts list are nay consistent. Blimey! That is, me hearties, me hearties, thar are too many dimensions and they don't add up. I recommend disregardin' t' 10-5/16" dimension while keepin' t' others.

I used a plastic "toy lathe" t' turn t' balsa nose cones, me hearties, me hearties, baffle plug, arrr, and blow-out plug. Avast, me proud beauty! Avast! Blimey! T' lathe is a Toymax Toolmaster Workshop that, shiver me timbers, ya bilge rat, unfortunately, shiver me timbers, has been OOP since around 1997. Avast! Blimey! Without a lathe, shiver me timbers, arrr, you should be able t' order t' nose cones and baffle plug from Balsa Machinin' Services. Ahoy! T' blow-out plug should be doable too, if you figure out t' dimensions t' specify.

Instead o' usin' 3" wide flats, I used 4" wide balsa flats for t' wings and rudder. Begad! T' do this, ya bilge rat, matey, shiver me timbers, I drew t' full-scale outlines o' t' completed win' and rudder, based on given patterns, then divided them up into 4" strips. I feel that this lead t' simplified assembly by reducin' t' number o' joints that needed fittin' together.

Once all o' t' parts had been fabricated, followin' t' assembly instructions be straightforward but still posin' some interestin' challenges. Ya scallywag! Blimey! Well, ya bilge rat, blow me down! Blimey! Matchin' duct slots had t' be cut into different caliber 14" tubes, arrr, then had t' be carefully sealed together with glue joints and fillets. Avast, me proud beauty! Blimey! Well, matey, blow me down! Blimey! T' win' and rudder parts needed careful trimmin' for precise fit.