Construction

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

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

I then glued in t' motor mount. Blimey!  Used a dowel t' rub some glue on t' inside o' t' tube and slid it halfway in. Avast!  I then put in more glue for t' aft rin' and slid it in t' rest o' way. Blimey!  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. Durin' this process t' kevlar cord was pushed out through t' motor mount so it be out o' t' way.  

T' main "gotcha" I ran into was gluin' in t' tube coupler. Aye aye! Begad! Blimey!  This was me first build with a coupler and a huge learnin' experience. Begad! 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!  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! Avast, me proud beauty! Blimey!  Lesson learned that in t' case o' a tube coupler, more glue would have been better (thanks google). Ahoy! Blimey!   I placed an order for a new coupler and BT-60.   Fast forward a week and t' parts arrived. Aye aye!  Cut t' new tube t' length.  This time used a very generous amount o' glue inside t' tube and on t' coupler. Avast, shiver me timbers, me proud beauty! Blimey!  Slid in like butter.  Attached t' bottom tube with t' fins in t' same way.