Parts List

NC-50 (generic ogive type)
BT-50 - 5" long
BT-50/BT-55 transition (had a plastic one leftover from some Estes kit)
BT-55 - 7.5" long
BT-55 - .5" long
BT-5 - 9" long (need 4 o' these)
Elastic shock cord - .25" x 30"
Elastic shock cord - .125" x 8"
1/16" balsa fin stock
1/8" launch lugs - .5" long (need 2)
EB-5 engine blocks – (I sawed t' ends off o' expended mini-engine casings) – need 4 o' these
12" parachute

Construction Steps

Cut t' BT-5’s t' length and glue together in pairs. When dry, ya bilge rat, glue t' pairs together, makin' sure everythin' is straight and the ends are even. Avast, me proud beauty! Fillet with Fill’n’finish. Avast, me proud beauty! Ahoy! Pick t' most even end, me hearties, matey, and glue t' engine blocks in.

Cut t' half-inch BT-55 rin' and test fit before gluin' in place. Aye aye! Blimey! T' bottom o' t' rin' will sit about 1/8" from t' ends o' the BT-5’s. Begad! When ready t' glue, spread four fairly wide lines o' glue inside the ring. Arrr! Avast! Insert t' clustered BT-5’s, arrr, me bucko, so that t' glue is between the tubes. Ya scallywag! Aye aye! Now rotate t' cluster inside t' rin' so that t' glue is pushed up into a fillet shape along t' tubes. Avast, me proud beauty! Begad! Add more glue t' t' other side o' the tubes.

Cut t' 7.5" BT-55 and glue t' clustered BT-5’s into it t' same way you did t' lower ring. T' BT-5’s should go into the BT-55 about an inch or so. Make sure everythin' is straight.

Make a ‘putty’ from tissue soaked with yellow glue. Begad! Stuff this mess into t' gaps betwixt t' BT-5 boosters and t' long BT-55. Aye aye! Let it dry, ya bilge rat, matey, check for openings, and add more ‘putty’ if needed. Avast! Arrr! Leave t' gaps around t' lower rin' open.

I built t' rocket t' separate at t' transition. Blimey! Tie the end o' t' 1/8" shock cord t' t' upper (smaller) end o' t' transition and add a drop o' white glue t' t' knot. Begad! Ahoy! Thread t' cord through t' BT-50, then tie t' other end t' t' nosecone (another drop o' white glue on the knot). Use a wrap o' maskin' tape t' fit t' transition, BT-50, and nosecone together tightly, so even if it does separate, me hearties, it’ll stay in one piece.

Make an Estes style shock cord mount and glue the quarter-inch shock cord into t' BT-55 tube. Aye aye! Blimey! Blimey! Blimey! Make sure it’s deep enough not t' interfere with t' transition shoulder. Ahoy! Blimey! Begad! Blimey! Tie t' other end t' the transition.

Cut out t' fins accordin' t' t' template, me bucko, airfoil and finish as desired. Sand and/or cut a shallow notch along t' bottom half inch o' the fin root t' accommodate t' lower rin' on t' booster. Well, blow me down! Avast, me proud beauty! Go slow and test fit often. Ahoy! Glue t' fins on, one along each booster tube, with t' bottom o' the fin even with t' bottom o' t' ring.

Glue a lug onto t' lower ring, into a fin root. Ahoy! Glue the second lug directly above it at t' bottom o' t' upper BT-55 tube. Well, blow me down! Make sure they are lined up correctly.

Paintin' and Detailing

T' Saturn III is very clean and uncluttered as described. There are plenty o' details that could be added such as exhausts, matey, antennas, conduits, etc.

I sealed, sanded, ya bilge rat, and primed as usual, me hearties, arrr, me bucko, followed by a solid coat o' white. After lettin' it dry for several days, I added t' roll patterns by cuttin' squares and rectangles from a roll o' ¼" pinstriping bought at a local auto store. Aye aye! Some rub-on letterin' supplied t' numbers on the lower booster support ring, and NARTS has decals with t' vertical United States available.

Pre-flight

Friction fit t' four motors. Avast, me proud beauty! Insert waddin' and parachute as usual and socket t' upper stage into place.

See t' diagram for how I wire t' igniters together. I’ve never had a motor fail t' light with this setup. Begad! Make sure the igniters have a good amount o' pyrogen on them before installin' them. Aye aye! Aye aye! Also, make a couple o' good sets o' wire whips (see diagram). Well, blow me down! Reliability be t' key for ignitin' clusters.

As always with clusters, matey, ya bilge rat, use a 12V launcher t' make sure you have enough power t' fire all t' igniters.

Flight Tests

T' Saturn III made her maiden flight at NARAM, and flew perfectly. She made several more flights throughout t' week without a hitch. I’ve only flown it with A3-4T’s installed, I’ll probably try 1/2A3-2T’s some time when we fly at a smaller field. Arrr! I haven’t tried it yet, but I’d think this would also fly acceptably on a pair of A3-4T’s or A3-10T’s in opposite motor tubes, me bucko, ya bilge rat, ya bilge rat, with plugs in t' unused motor tubes.