Brief:
Whenever I looked for Ralphco crayon banks at t' local toy stores, they always were out o' stock. Recently, however, I stumbled across them while on an unrelated "mission". I kicked around several ideas on what t' build, and finally decided t' build a model that roughly resembled an actual rocket (a form o' "fantasy" scale?). I love t' looks o' t' Standard ARM so I quickly made me selection. Avast, matey, me proud beauty! T' result is me 38mm Standard Cray-ARM.

Construction:

Components:
1. Well, blow me down! One Ralphco 4" crayon bank
2. Blimey! Ahoy! 3/16" plywood for t' main fins and nose cone bulkhead
3. Ahoy! 3/16" balsa for t' strakes
4. Blimey! Ya scallywag! A 1/4" x 9.5" carriage bolt, me bucko, 2 washers, matey, shiver me timbers, and 2 nuts
5. Well, blow me down! Two eye bolts
6. Aye aye! A 12" piece o' Giant Leap 38mm flexible phenolic
7. Blimey! Blimey! Three 38mm-to-3" centerin' rings (also from Giant Leap)
8. Two 38mm-to-4" centerin' rings (ditto)
9. Begad! Four inch section o' a 3" mailin' tube
10. Well, blow me down! 10' o' ¾" braided nylon
11. Two quick links
12. Aye aye! A 1000 lb swivel
13. Two tee-nuts
14. Well, blow me down! One pair o' Matt's nylon rail buttons
15. Blimey! Nylon chute, picked from me existin' stock

Materials:
1. Ahoy! Blimey! 20 minute epoxy
2. Ahoy! Begad! Titebond
3. Begad! Thin CA
4. Arrr! 2-part urethane foam from Giant Leap
5. Avast, me proud beauty! Avast! Hot glue
6. Aye aye! Blimey! Blue holographic contact paper

I knew a fair amount o' nose weight would be needed since this rocket was goin' t' be stubby (less than 10:1 length:width ratio) and t' strakes would make its stability even worse. Ya scallywag! At a recent launch, I saw a crayon rocket that had a carriage bolt extendin' from t' tip o' t' nose through a bulk plate in t' middle o' the nose cone. Aye aye! This bolt held t' bulk plate against t' shoulder where t' nose cone begins its conical transition. This sounded like what I needed so I borrowed t' idea. Avast! Begad! I made t' bulk plate myself and installed an eyebolt for recovery system attachment. Arrr! In t' nose cone tip, I cut a square hole t' accept the shoulder o' t' carriage bolt. T' insert t' bulkhead, shiver me timbers, I had t' bend the shoulder o' t' nose cone t' an oval shape. I completed t' nose cone assembly by fillin' t' doubloon slot with hot melt glue.

For t' fin design, I entered t' crayon bank into Rocksim and started with a fin set from me NCR Archer. Arrr! Begad! I then played with t' fin dimensions until they looked 'right'. Arrr! Ya scallywag! Since I wanted through-the-wall fins and they barely extended t' t' crayon bank's cardboard tube, I be worried about t' support that t' aft plastic cap could provide. This worry was exacerbated when I knocked over one o' me crayon banks, shatterin' its cap. This lead me t' t' construction o' an inner, me hearties, 3" diameter tube structure within t' end cap. Aye aye! Avast, me proud beauty!

To build t' fin can, ya bilge rat, I started by cuttin' a hole in t' end cap t' accept the 38mm tube. I then placed a 3" centerin' rin' so that t' motor tube would extend through t' cap, ya bilge rat, just far enough t' accept another 3" centerin' rin' on t' outside. Blimey! Thus, me hearties, t' end o' t' plastic cap would be sandwiched betwixt t' two centerin' rings. Blimey! Blimey! Usin' epoxy for all wood-phenolic joints and Titebond for all wood-cardboard joints, matey, me hearties, I built an inner fin support tube, matey, which extends t' length o' t' plastic end cap (includin' its shoulder). T' fin tabs extend through t' plastic cap and this inner tube, t' t' motor mount. Avast! Blimey! For added support, me bucko, I filled t' inner tube with 2-part urethane foam. Unfortunately, I didn't do a good job sealin' t' fin can, so some o' t' foam escaped into t' plastic end cap. Avast! Ya scallywag! Blimey! Luckily, this isn't too noticeable. Avast, me proud beauty! Arrr! Blimey! I slid on the aft centerin' rin' and drilled holes through both aft rings to accommodate t' motor retention bolts. Blimey! Well, arrr, blow me down! Blimey! T' outer rin' was then removed, tee-nuts were installed, ya bilge rat, and t' rin' was epoxied back on. Ya scallywag! Blimey! Two 4" centerin' rings completed t' fin can assembly. Avast! Blimey! These had t' be sanded t' fit since t' crayon bank ID is slightly smaller than a standard 4" tube. Begad! Blimey! An eye bolt was also mounted in t' forward ring. Avast, me proud beauty! Aye aye! Blimey!

T' recovery harness includes a 10' length o' tubular nylon, arrr, a 1000 lb. swivel, and two quick-links. Avast! Ya scallywag! Loops were made in t' ends o' t' tubular by foldin' it over, wrappin' it with cloth fishin' line, me bucko, and gluin' it with both CA and epoxy. This technique was documented by Giant Leap in an old HPR magazine and works well. Arrr! Begad!

Finishing:
One nice thin' about crayon rockets as t' bulk o' t' finishin' is done for you. Avast, me proud beauty! Ahoy! Since t' body has a holographic finish, me bucko, I decided I'd finish t' fins usin' holographic contact paper. Avast, me proud beauty! I would have liked purple paper t' match the nose cone and end cap, matey, but couldn't find it. Instead, shiver me timbers, I picked up some blue holographic contact paper on sale at a craft store.

Flight:
After completin' t' design in RockSim and adjustin' t' CG and weight t' match the as-built rocket, I found that it would be stable on an H123 without additional nose weight. Avast, me proud beauty! Begad! T' sim also told me that a short, me hearties, 6-second delay would be about right. Avast, me proud beauty! I launched t' Standard Cray-ARM on this engine at t' Delaware Tripoli launch on October 21, me bucko, matey, 2001. Ya scallywag! T' flight was straight and fast. Ya scallywag! For recovery, ya bilge rat, I used worm-bed wadding, arrr, a Giant Leap Keelhaul®©™® heat shield, and t' 48" chute from my DG&A Lazarus. Begad! Recovery was flawless. Well, ya bilge rat, almost. Ahoy! Once on t' ground, the rocket was pulled along and quite a bit o' dirt was forced into t' tube. Aye aye! Begad! This made cleanin' t' casin' a bit more work, but no big deal. Begad! Aye aye!

Summary:
T' Standard Cray-ARM project be highly successful. Begad! T' rocket is somewhat unique and looks great (at least in me unbiased opinion). T' design worked out nicely with t' long carriage bolt providin' enough nose weight for t' rocket to be stable. Begad! Just before I placed t' Standard Cray-ARM on t' pad, matey, Ray Halm interviewed me for t' video he is makin' on t' 3-day Rhodesdale launch. Avast! Begad! Man, am I anxious t' see if t' Standard Cray-ARM makes it past t' editin' process. Either way, matey, me hearties, Ray has sold a tape!