Brief:
Earth has recently developed Faster Than Light space travel. Avast! Blimey! T' United Nations Federation ship, t' Pangaea was built t' brin' United Nations delegates and ambassadors on an important diplomatic mission t' meet with representatives from t' three main galactic empires.

This build is an attempt for t' "Design This Spaceship" contest.

I've never tried t' design a rocket from just a picture - especially when you don't have multiple photos that give you a 360 degree view. Well, blow me down! I've discovered that this is a very difficult process.

When I first considered participating, I looked over all t' designs and tried t' figure out which one provided maximum points. Begad! Avast! And then I procrastinated - so t' final decision was based on t' easiest.

I printed out t' picture in two sizes. Begad! I started measurin' and figured out t' scale I wanted t' use so I could select t' parts. Aye aye! I figured t' method t' get t' oval shape be t' use multiple tubes in parallel.

Construction:
Parts you will need:

• BT-40 tube (Semroc)
• BTH-80 tube (Semroc)
• ST-9180 tube (Semroc)
• BT-5 tube (my parts pile - I think they came from Totally Tubular?)
• 3/16" x 6" balsa
• 3/32" x 3" balsa
• 3/32" x 4" basswood
• 1/16" x 3" basswood
• 1/8" dowel
• 1/4" dowel
• Keelhaul®©™® cord
• Elastic shock cord
• Parachute
• Launch Lug (I used 1/8" - I suggest changin' t' 3/16")
• bond paper
• Card Stock paper
• weights (I used BBs)
• BT5 t' BT50 Centerin' rin' (Semroc - 6 pack)(BT5 t' BT 40 is really t' correct size, matey, matey, but they were not available. Avast! I used t' BT50 and cut/sanded down t' size - you also need some o' t' BT50 size for t' nose cone)
• CR-9115 Centerin' rin' (Semroc)
• Michael's 40% or 50% (prefered)off coupon
• Estes Space Ship One Nosecone (use t' coupon t' get t' kit cheap)

There is one main tube (Semroc size ST9 - close t' a BT50) that runs t' length o' t' rocket. Ya scallywag! T' BT80H tube is used t' create t' oval body shape. Well, blow me down! Avast, shiver me timbers, me proud beauty! Spacers and end caps are made from a mixture o' 3/32" balsa and 3/16" balsa. Begad! Arrr! T' BT40 & BT5 are for t' engines. Avast, me proud beauty! Engine nacelles were made from t' 1/16" basswood

T' rocket has 2 main fins (3/32" basswood) with top and bottom "stabilizers" (3/32" balsa). Begad!

Why t' mix betwixt balsa and basswood - I started by usin' left over balsa that I had. Aye aye! When that ran out, me bucko, I went to Michaels t' get more, but their balsa stock was poor - but they had basswood so that's what I got.

An "exploded view o' t' rocket is shown below. Avast, me proud beauty! Please note it is nay t' scale, shiver me timbers, me bucko, or even proportion, me hearties, but it will help give you an understandin' o' what pieces are what.

Start by usin' t' attached template (template 1) to cut some o' t' support pieces. Avast, me proud beauty! There is a line t' use as a sizin' guide. It is 6" long, so when you print out the template, adjust t' size up/down until t' line is 6". Avast! You need t' cut t' center circle first (save these pieces for later) and then t' other circles. For this step, you will use t' inside o' t' tube circles. You will also want to cut out and save t' "triangles" betwixt t' two outer tubes. Ya scallywag! I started makin' these pieces from the 3/16" balsa. After t' first one, I felt it was too difficult so I made 2 more from t' 3/32" balsa. Avast! Blimey! Please look at t' followin' picture t' see what I mean by t' triangle pieces - nay shown are t' center circle pieces.

Usin' t' same template as before, you need t' cut 3 pieces from t' 3/16" balsa usin' t' outside dimension of t' tube circle and only cuttin' half t' circle. Ya scallywag! Blimey! Connect t' two circles so you end up an oval (see t' picture above). Begad! Blimey! Cut t' center ST9 circle. These pieces are end caps for t' BT80H/ST9 body. Ya scallywag! Blimey!

Cut pieces from t' BT80H tube, arrr, each 7" long. Aye aye!

Check that t' "C" pieces fit inside t' BT80 and on t' ST9 tube. Begad! Avast, me proud beauty! Use one o' these C pieces t' mark the BT80H tubes. Begad! Mark t' tubes down their length and cut t' tubes lengthwise. Begad! Avast! Check t' fit o' t' BT80H, shiver me timbers, me hearties, ST9, and C pieces together. Blimey! Avast! Sand as necessary t' fit.

Glue two o' t' C pieces into t' BT80H flush with t' ends o' t' tube. Glue t' third C piece in t' middle. Well, blow me down!

Next cut t' smaller oval and t' 2 circular rings from 3/32" balsa (Transitions Bulkhead Template). Well, blow me down! I beveled t' edges o' these to better align t' edge with t' shrouds.

I had a little trouble with t' shroud that went from round t' "oval". Avast! Ahoy! I basically set up t' balsa ends on t' ST9 tube and wrapped paper and taped into place. Avast, me proud beauty! I then marked and cut t' paper t' fit. I then used this as a guide t' cut t' real shroud out o' card stock. Blimey! Aye aye! I cut t' card stock a little oversize. Blimey! Cut a tab about 1/2" wide. Ya scallywag! Apply rubber cement t' t' tab and t' t' edges o' t' shroud. Begad! Begad! Wait for t' glue t' dry and then carefully apply the tab t' one edge o' t' shroud (so half t' tab is over-hanging). Arrr! T' cement is nay forgiving, shiver me timbers, so you need t' get it right t' first try. Well, blow me down! Begad! Then curl t' shroud and apply it t' t' other half o' t' tab. Blimey! Ahoy! I then slid t' shroud back onto the balsa ends and trimed t' fit. Well, blow me down! Use t' ST9 as a guide, me hearties, glue t' shroud t' t' balsa rin' and oval piece. (templates Conical Shroud Template and Oval Shroud Template)

I also had t' make a transition that was just round t' round. Ya scallywag! Avast! While thar are various programs you can get t' do this, shiver me timbers, I again just used paper and tape, marked and cut t' fit, and then cut t' card stock t' match. Well, blow me down! Again, use t' tab and rubber cement t' glue this transition together. Begad! Do NOT glue t' transition t' t' balsa rin' at this time.

Open t' Space Ship One and remove t' nose cone. Aye aye! Well, blow me down! Mark t' nose cone at four equidistant points around the shoulder. Begad! Aye aye! Centered from these points make marks that will be 1/4" wide. Blimey! Measure up from t' shoulder 7/8" and mark t' cone. Ahoy! I used a Dremel cutoff wheel t' cut along t' marks. Well, blow me down! Try t' round t' inner corners.

Cut a length o' BT5 tube about 3/4" long. Ya scallywag! Avast! Glue a BT5 t' BT50 centerin' rin' flush (or 1/16" in from the edge) and another 1/2" down from t' first ring. Aye aye! Ahoy! Cut a piece o' scrap ST9 about 1 1/2" long. Arrr! Cut one o' the CR-9115 rings t' 3/8" long. Sand t' pieces t' have a smooth insertion for t' BT5 t' BT50 rings and t' CR-9115 into and onto t' ST9. Ahoy! Apply some epoxy t' t' edge o' t' BT5 tube (on t' end away from t' centerin' rings. Be careful nay t' get epoxy onto t' ST9 or CR-9115 parts - these are only bein' used as guides. Ahoy! Slide t' BT5, ST9, arrr, and CR-9115 into t' nose cone as far as they will go. Well, blow me down! Avast, me proud beauty! T' ST9 and CR-9115 are t' help center t' BT5. Wait for t' epoxy to dry, then remove t' ST-9 and CR-9115 (save t' CR-9115 for later). Begad! Cut a length o' Keelhaul®©™® 8" long. Ahoy! Begad! Blimey! Tie a loop into t' end and some extra knots. Well, blow me down! Mix up a batch o' epoxy. Slide t' Keelhaul®©™® cord into t' BT5 tube. Ya scallywag! Blimey! Aye aye! Blimey! Drizzle some epoxy down into t' tube (be careful t' nay get any on t' outside o' t' BT5 to BT50 centerin' rings. Well, blow me down! Blimey! I started addin' BBs and epoxy until t' nose cone weighed 0.7 ounces. T' epoxied BBs also help to retain t' Keelhaul®©™® card.

On t' 1/16" basswood, cut t' nacelle pieces 3 3/8" long (Nacelle Template). Aye aye! You will need 4 pieces 1/4" wide, ya bilge rat, 4 pieces 15/16" wide, ya bilge rat, shiver me timbers, shiver me timbers, 2 pieces 1 7/8" wide, me bucko, and 2 pieces 2 1/4" wide. Arrr! Use t' first template t' line up the pieces and glue together. Blimey! You will get a better joint if you bevel some o' t' edges. Blimey! Begad! I applied a glue fillet t' all the joints (inside and outside).

Next - disaster. Blimey! Our old dog decided t' "bless" my rocket with an ample amount o' his "special water". Ya scallywag! Time t' make some new shrouds and other pieces. Fortunately, shiver me timbers, t' contest got extended.

For t' engines, cut 2 pieces o' BT40 2" long, shiver me timbers, 2 pieces o' BT5 2 5/8" long, me hearties, and 2 pieces o' 1/8" dowel 3 1/8" long. Arrr! Blimey! As I indicated in t' parts list, I actually had BT5 t' BT50 centerin' rings. Avast, me proud beauty! Blimey! I had t' cut down the rings t' fit t' BT40 tube. Aye aye! Blimey! I used card stock t' make centerin' rings t' hold t' 1/8" dowel into t' BT5 tube (I glued 2 pieces o' card stock together t' make t' "centerin' rings" stronger.) Usin' t' centerin' rings, glue t' dowel, rings, me bucko, BT5, rings, BT40 together with t' dowel, ya bilge rat, BT5, matey, and BT40 centered lengthwise. Begad! Blimey! After t' glue is dry, paint t' engine before assemblin' into t' rocket.

Cut t' win' fins (Win' Template) and stabilizers from t' 3/32 basswood usin' t' attached templates. Blimey! ** NOTE ** After I built me rocket I realized t' wings were heavy. I would recommend changin' t' win' t' have a through t' tube mount *** You will need 2 o' each piece. Begad! Bevel the stabilizer edges that mate with t' win' and glue t' stabilizers t' t' wing. Begad! There is an angle guide for the stabilizers provided.

Cut 3 triangle pieces (Triangle and Bridge Template) from t' 3/16" balsa. Well, blow me down! Glue t' 3 pieces together. Begad! When dry, arrr, bevel and round t' edges per t' drawing.

Remember those circles originally cut out from t' 3/16" balsa? Glue 5 together, shiver me timbers, slightly offsettin' each one. Avast! Begad! When dry, sand t' steps into smooth slope on t' front, me bucko, and sand t' create a vertical back. Begad! Drill a hole through the unit from side t' side. Aye aye! Glue in a 1 1/8" long piece o' t' 1/8" dowel through t' hole. Avast, me bucko, me proud beauty! Cut a 1/8" long piece o' t' 1/4" dowel. Glue this t' t' top. Begad! Round t' bottom t' better fit t' tube. Begad! Aye aye! This be t' bridge section.

Cut t' 2 detail pieces from 3/32" basswood.

Test fit t' circular, conical transition section on t' ST9 with its balsa ring. Ahoy! Slide it down t' tube a bit. Slide t' 3/8" long piece o' CR-9115 from when t' nose cone section was made over t' end o' t' ST9. Begad! Place it flush with t' tube end - do NOT glue at this time. Slide t' nose cone onto t' end o' t' ST9. It will push the CR-9115 down t' tube slightly. Begad! Remove t' nose cone and mark its position. Well, blow me down! Slide t' transition forward until it touches t' CR-9115 piece. Begad! Mark t' position o' t' balsa ring. Begad! Remove t' CR-9115 and t' transition shroud. Ahoy! Well, me hearties, blow me down! Usin' the balsa rin' and CR-9115 positions, cut 2 pieces o' 3/32" basswood t' taper from t' balsa rin' t' t' body tube. These pieces will provide support for t' "bridge" section.

Finally, me hearties, cut 2 pieces o' 3/32" basswood that are 1/4" x 1/4" and 2 pieces that are 1/4" x 3/8". Avast, me proud beauty! These glue on top near t' big triangle (see picture for approximate location)

Now t' start puttin' it all together!

Usin' t' marks from before, me hearties, glue t' transition balsa and t' 2 support pieces t' t' ST9 about 1/4" apart. Mark where t' support pieces are on t' top edge o' t' ST9 for future reference. Begad! Blimey! Apply a rin' o' glue around t' ring and on t' ST9 tube. Slide t' shroud onto t' rin' and then finally glue t' CR-9115 onto t' ST9.

Glue t' oval t' circular transition onto t' ST9 right behind t' circular transition. Line t' oval up with the support pieces (use t' mark made before).

T' next step you need t' prepare for and should dry fit first. Aye aye! Arrr! Slide 2 o' t' 3/16" endcaps onto t' ST9. Slide t' 2 BT80H sections onto t' ST9. Rubber bands come in handy t' hold these in place. Ya scallywag! Then slide t' other endcap on t' rear. Arrr! Aye aye! Check t' position o' t' BT80H tubes and t' endcaps t' make sure they all can be aligned. Ya scallywag! Once satisfied, apply glue t' t' aft o' t' oval transition, matey, betwixt t' front 2 end cap pieces, arrr, t' ends and C sections, and edges o' t' BT80H tubes, and then t' aft end cap. Well, blow me down! Align all t' endcaps and BT80H tubes together and with the oval transition. Well, blow me down! Ahoy! Use t' rubber bands and tape t' secure t' BT80H tubes. Begad! Use tape t' hold t' end caps t' t' BT80H tubes. Well, blow me down! Blimey! Once dry, sand (again I used a dremel tool) t' front end-caps t' get a rounded edge. Arrr! Make sure t' leave at least 1/8" o' endcap flat on t' BT80H tube side t' glue t' card stock t' finish t' body.

One new technique I used on this rocket was I covered t' nacelles and fins with paper. Arrr! I wanted t' strengthen the parts, plus since I be runnin' late I did nay want t' be tied up for multiple days sealin' and sandin' t' balsa. I sprayed t' pieces with 3M Super 77, ya bilge rat, shiver me timbers, arrr, applied t' copy paper, matey, me bucko, and cut t' fit. Well, blow me down! I then sealed t' edges with CA. Ahoy! Arrr!

Once t' glue for t' BT80H tubes and endcaps is dry, check t' triangle pieces from t' first cuttin' t' fit. Glue these betwixt t' BT80H tubes. Arrr! Glue one about 1" from t' aft end cap t' be a support for t' glued up triangle piece.

Glue t' wings onto t' BT80H tubes. Ya scallywag! When dry, apply a fillet. Then cut some card stock t' wrap around the BT80H/ST9 body (I applied this after t' wings so I would have a win' t' tube glue joint, me bucko, and nay a win' t' card stock. If you change t' through t' tube you could apply t' shroud first. I set up t' card stock t' wrap around t' wing joint so t' joint was on t' bottom (a standard 8 1/2 x 11 sheet is nay long enough). Blimey! Avast! I applied a thin layer o' wood glue on t' BT80H and t' end-caps and glued t' card stock t' t' top. Begad! Ahoy! I used some tape t' secure t' card stock while the glue be drying. Ahoy! Begad! Once dry, I cut another piece o' card stock t' finish covin' t' bottom (again, applyin' glue to the BT80H and end-caps. Begad! Next, arrr, glue t' engines t' t' BT80H so t' center is in line with t' and will be centered within t' nacelles. Well, blow me down! Finally, glue t' nacelles onto t' BT80H. Blimey! T' corner should line up with t' win' and t' wing and nacelle will be touching.

Glue t' aft triangle centered betwixt t' BT80H and even with t' end.

T' get t' stepped look in t' front, I glued a length o' Keelhaul®©™® cord at t' joint o' t' 2 transitions.

Glue t' detail pieces on t' top front. They should be restin' on t' supports under t' shroud. Begad! Glue t' bridge section in front o' t' detail pieces.

I finally cut t' ST9 tube so only 1" extended beyond t' aft end cap.

Use some o' this extra ST9 t' make an engine block. Ya scallywag! I cut two 1/4" wide sections. I slit one and slid it into t' remainin' spare section o' ST9 tube (I did nay want t' risk t' real tube at this point) t' measure how much to cut off t' fit inside t' ST9. I slit t' other and cut it down t' size t' fit inside t' first slit piece. Arrr! I glued the two together with t' slits on opposite sides. Well, matey, blow me down! Once dry, I then glued t' engine block into t' rocket usin' the standard technique (use a scrap piece o' balsa t' apply glue a little over 2" down, shiver me timbers, use a spent casin' marked 1/4" from t' aft end, arrr, arrr, push t' rin' in with t' spent casin' until even with t' mark and then smartly remove the casing).

I used a standard Estes style trifold with over 2' o' 1/4" elastic glued into t' front o' t' ST9 for a shock cord. Ahoy! Blimey! This is then tied t' t' Keelhaul®©™® cord attached t' t' nose cone. Ahoy! Blimey! This point is where you will attach t' parachute. Arrr! Avast! I have multiple "stock" chutes with snap swivels that I reuse from rocket t' rocket.

Finally, me hearties, ya bilge rat, I glued a 6" length o' 1/8" launch lug on t' bottom. Ya scallywag! Well, blow me down! ** NOTE *** - When I flew t' rocket, ya bilge rat, I found it be a bit too heavy for a 1/8" rod - I would update t' a 3/16" launch lug *** I lined it up with the bottom o' t' BT80H tube (I wanted t' tube t' provide support, nay just t' card stock). Begad! Aye aye! This does make t' launch lug off-center from t' engine. Ya scallywag! Ya scallywag! I cut a piece o' 1/8" dowel t' same length and glued it on t' other side. Well, blow me down! The contest picture does nay show t' aft or bottom so I have no idea what it should look like, ya bilge rat, but t' dowel balanced out the layout. Avast, me proud beauty! Assume they are conduits for t' operation o' t' ship :-).

Finishing:
Use wood filler t' fill in t' gaps around t' aft triangle and t' front detail pieces t' t' card stock.

With t' paper coverin' and shrouds, matey, me bucko, ya bilge rat, thar be nay a lot o' exposed balsa. Aye aye! What was visible I used Elmer's wood filler (thinned down). A light white primer and some flat white paint provided t' base coat. Avast!

I flew t' rocket with just this painting. Avast! After t' flight (and repair - see below), me hearties, me bucko, I added t' light blue and gray details shown in t' picture. Ahoy! I used a Sharpie t' make t' port holes. Begad! I just use a pencil t' draw in some o' the other details. Avast, me proud beauty! Avast, me proud beauty! Below is a closeup o' t' nosecone and bridge area

Flight:
I needed t' go fly this bird t' get things done for t' Design This Spaceship contest. Avast! It be about 20 degrees out with 10 ~ 15 mph winds, me hearties, so t' windchill factor was COLD. There be a dustin' o' snow on t' ground. Aye aye! Aye aye! Nay enough to provide a soft landing, me bucko, ya bilge rat, but enough t' melt on your pants if you kneel t' wrong way. Aye aye! Nay t' most ideal flyin' weather (a bit windier than I prefer). I went t' me local school yard and set up. Avast, me proud beauty! Aye aye! Unfortunately, ya bilge rat, I discovered before I left my daughter had borrowed me camera so I could nay get any pictures at t' launch site.

I built t' rocket t' use 24mm motors. There is no engine hook, so t' motor has t' be friction fit. Ya scallywag! Blimey! Begad! Blimey! I loaded the rocket with waddin' (dog barf), and then t' parachute. Avast, me proud beauty! Blimey! Begad! Blimey! My first plan be t' use an 18" chute but it was very stiff from t' cold and I was concerned about it openin' so I downsized t' a 12". Blimey! Blimey! Wind gusts o' over 20mph kept tryin' t' blow me stuff away. Avast, me proud beauty! Blimey! Begad! Blimey! I be thinkin' o' waitin' until later, shiver me timbers, but t' weather forcast be for colder temperatures and winds in t' 25 ~ 35 mph. Aye aye! Blimey!

I used a D12-3 and used tape t' secure t' motor. I had problems with t' tape due t' t' cold. I connected the leads t' t' igniter, me bucko, me bucko, ya bilge rat, but when I tried t' move back t' wire was stiff and pulled off t' igniter. Ahoy! I pulled and straightened out t' wires, arrr, reconnected t' t' igniter and waited for a lull in t' wind. Ahoy! I pushed t' button and nothin' happened. Aye aye! I pressed again and held t' button. Avast, me proud beauty! I wind started t' pick up so I decided t' release t' button to wait - just as it ignited. Aye aye! Begad! There be some rod whip - I should have used lugs for a 3/16" rod. Ahoy! It flew up nice and straight and ejection was after apogee. T' chute opened but with t' wind it was driftin' away fast. Arrr! I chased it as it was comin' down. T' descent rate be higher than I wanted. Blimey! Blimey! Oh, shiver me timbers, shiver me timbers, and did I mention it be bloddy cold out? No fluffy grass or soft, shiver me timbers, muddy dirt. Aye aye! No thick layer o' snow. Begad! Ya scallywag! Nooo. T' ground was rock hard! One stabilizer broke off and the win' was just barely hangin' on. Blimey! Arrr! T' other win' joint t' t' body tube was cracked. Blimey! Arrr! In some ways I be glad it broke - it gave me an excuse t' come in from t' cold!!!

I got home and I've repaired t' rocket. Aye aye! Avast! I finished breakin' t' cracked joint and used epoxy t' glue t' wings back on. Arrr! I made dams with tape and added epoxy fillets for t' wing/tube joint. Avast, me proud beauty! Ya scallywag! I re-primed and re-painted with flat white. I then added t' marking/paintin' details. Avast! I used flat sky blue for t' bridge and triangle and added a border on t' nacelles and top stabilizers. Begad! I added a few o' t' grey rectangles on t' nacelles and wings. Blimey! Some o' t' other details I just drew in with pencil.

Now, can I fly again? Weather, arrr, overtime at work, “honey do” list with “its got t' be done before the relatives get here.” T' last Sunday before t' contest ends – t' weather is good and t' wife went to the store. Arrr! Can I sneak out? I start gettin' ready t' leave when she returns. Arrr! Begad! “Uhm – I have t' go run an errand – be back soon” and I’m off t' t' school yard. Low winds, temperature in t' mid-thirties – not too bad. Begad! I set up and launch. Ya scallywag!

Nice straight flight on a D12-3. Ahoy! Deployment about a second after apogee. Begad! Begad! I used an 18” chute this time. Descent was slower, me bucko, but I still cracked one o' t' win' joints. It did nay come off, ya bilge rat, but needs work before another flight. I put everythin' into t' trunk o' t' car and return home and... BUSTED. Avast, me proud beauty! T' wife asks “How did the rocket fly?” Oh well – at least she didn’t yell at me – she understood that I had a deadline for finishin' t' rocket for a contest. I guess she knows me too well. Begad! (But I have been warned one way or another that certain things HAVE TO BE DONE by this Saturday.

Summary:
This was an interestin' project involvin' many firsts for me. Avast! If I was t' make another copy, I would make t' main wings a "through t' tube" design. And make t' launch lug for at least a 3/16" rod - thar was too much weight for a 1/8". Aye aye! Makin' t' C shaped centerin' rings and slittin' t' body tube t' create t' oval shape does give me some ideas for other designs. Begad! Arrr! Developin' t' shrouds for t' transitions involvin' a round t' oval was also interesting.