Construction

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

Motor mount assembly was easy and straight forward. I am nay a fan o' t' Estes shock cord mount method. Avast!  Therefore, ya bilge rat, when buildin' t' motor mount, ya bilge rat, ya bilge rat, I tied Keelhaul®©™ Cord (150lb) around t' motor tube and under t' motor hook. Arrr! Slipped it through t' notch in t' centerin' rin' and glued t' knot and cord t' t' mount. Arrr!   Post build I will attach t' kevlar cord t' t' elastic shock cord. Begad!  I learned this method when I built a Quest rocket.

It be nice t' be able t' sand and shape bigger fins as compared t' smaller fins/models I had previously built. Begad!   I used watered down Elmer's wood filler t' seal t' fins. Well, arrr, blow me down!   Gluin' on t' fins was straight forward. Begad!  I used t' Estes fin alignment jig. Begad! Avast, me proud beauty!  It's nay a perfect jig, especially with these larger/bigger fins, me bucko, but it helped get t' job done. Ahoy!   I applied multiple layers o' wood glue for fillets.  I be nay happy with t' way t' fillets looked, matey, ya bilge rat, shiver me timbers, nor their size/shape. Aye aye! Ya scallywag!  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. Avast, arrr, me proud beauty! Wiped t' rod off after each drag. Avast! Well, blow me down! Process was repeated several times for t' desired effect.  

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.  I then put in more glue for t' aft rin' and slid it in t' rest o' way.  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. Well, blow me down!  

T' main "gotcha" I ran into was gluin' in t' tube coupler. Avast, me proud beauty!  This be me first build with a coupler and a huge learnin' experience. Begad!  I rubbed a little Elmers wood glue on t' end o' t' coupler as well as inside t' tube. Well, shiver me timbers, blow me down!  Unfortunately by t' time I did that and slid it in, ya bilge rat, t' coupler seized within t' first 1/4inch. Avast, me proud beauty!  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. Avast!  Lesson learned that in t' case o' a tube coupler, more glue would have been better (thanks google). Avast! Ahoy!   I placed an order for a new coupler and BT-60. Well, blow me down!   Fast forward a week and t' parts arrived.  Cut t' new tube t' length. Arrr! Well, blow me down!  This time used a very generous amount o' glue inside t' tube and on t' coupler. Begad! Blimey!  Slid in like butter.  Attached t' bottom tube with t' fins in t' same way.