Parts List:

• One Ace Nosecone (NC)
• One 4" by 16" piece o' balsaply (or equal)
• One 4" by 4" piece o' 1/4" plywood for bulkhead (BH)
• One 18" piece o' 3/8" wooden dowel
• One Print Out o' Ace Nosecone interior
• - Download Part One
• - Download Part Two
• 3 ounce fiberglass (glass)
• Epoxy laminatin' resin (like Systems 3 or West Systems)
• Cyanoacrylate (CA)
• 1 U-bolt
• 1 1" section o' 4" airframe tubin' (for retainer ring)
• 4 each #8 panel clips (from auto parts store)
• 4 each #8 by 1/2" screws
• 3M 77 (or equal) Spray Mount Adhesive

Download t' 2 templates and print out on your printer. There are 1" square boxes on each template t' indicate correct sizing, matey, you may have t' fiddle with your printer output t' get t' correct size. Blimey! These are .gif images. Arrr!

Once you have t' templates sized and printed cut them out and match t' two halves t' t' match line shown. Well, blow me down! The entire cone is drafted though you don't need them both if you don't intend t' make t' entire nosecone a payload section. Begad! My design only has t' last 6" or so o' t' cone interior as payload. T' lines are thar so you can cut to size as you choose. Begad! Begad!

Usin' a spray mount adhesive, glue t' template t' t' balsaply. Well, blow me down! Begad! Cut t' template t' rough shape. Usin' a sander or rasp or whatever, sand t' template t' it's final shape. Avast, me proud beauty! Begad! Don't attempt t' cut t' template out dead-on t' t' lines, it's much easier t' get it close then sand t' get it perfect. While you have this template cut your fiberglass cloth to fit, ya bilge rat, you need one piece this size. Ahoy! Once you have t' balsaply cut t' size, cut along t' dotted line. Begad! This is where the dowel goes. These two parts I am callin' "wings" for t' sake o' clarity. Take one win' and use it as a template t' cut an additional wing. Begad! This third win' becomes a "strong back" t' support t' two wings and dowel in t' cone. Begad! Usin' this win' as a template cut an additional two pieces o' glass, matey, but a bit oversize - maybe an inch wider. Ahoy! Set t' glass aside for later use. Avast, me proud beauty! Aye aye!

On t' second template thar be a bulkhead template. Glue this t' 1/4" ply and cut out. Well, matey, blow me down! Take t' Ace nosecone and trim off t' bottom part (where t' screw top thin' is). Blimey! Cut it right where t' wall intersects t' base. T' 1/4" ply bulkhead slides in here. Well, blow me down! Aye aye! Test fit t' bulkhead and sand as necessary t' get a good fit. If the bulkhead is oversize it will balloon t' shoulder o' t' NC and t' airframe (AF) tube won't fit. Arrr! Ya scallywag! Test it with a section o' AF you intend t' use. Ya scallywag! Drill a 3/8" hole in t' center o' t' bulkhead. Blimey! Drill two holes t' receive the U-bolt. Avast, me proud beauty!

I made t' dowel poke out t' tip o' t' nosecone because it was fun t' do. Avast! It's nay critical, arrr, you can simply make t' dowel shorter. Avast! Begad! T' purpose o' t' tip protudin' is t' center t' payload section in t' nosecone, a job the wings if cut properly can do.While you have t' nosecone in hand, whack off t' tip o' it so a 3/8" hole is developed. I used a bench grinder for this and it takes some grindin' and fitting. T' fit is important so make sure it's nice and snug, take your time. Arrr! Avast, arrr, me proud beauty!

Fit t' dowel into t' NC so an inch or so protrudes from t' tip. Aye aye! Add a bit o' yellow glue t' t' dowel just at the base o' t' shoulder line Slide t' bulkhead over t' dowel and into t' shoulder. Avast, shiver me timbers, me proud beauty! T' dowel is now square t' the NC if you trimmed t' tip properly. Begad! CA t' dowel t' t' bulkhead and remove by pullin' on t' dowel protrudin' from the bulkhead. Avast, me proud beauty! Clamp this is a vise or somethin' handy t' keep it from movin' around. Usin' yellow glue, shiver me timbers, glue t' three wings t' t' dowel. Begad! T' two wings in t' same plane are flush with t' tangent o' t' dowel cross section. T' third win' is at 90 degrees t' these wings. Begad! Let dry.

Get t' 1" piece o' airframe and cut it into 3 pieces. Arrr! Blimey! One piece will be 180 degrees and t' other two 90 degrees. You will need t' remove some o' t' tube t' make it fit inside t' wings, matey, a pair o' strong scissors works well. Begad! Blimey! When fittin' t' pieces, me hearties, make sure that they are nay flush with t' edge o' t' bulkhead. Ahoy! Blimey! Hold them back off the edge (towards t' dowel) as t' panel clips need t' clear t' shoulder o' t' nosecone. Blimey! Blimey! Glue these pieces t' the bulkhead and t' t' wings. Ya scallywag! Blimey! This becomes t' retainer ring. Well, me bucko, blow me down! Blimey!

Test fit t' part in t' nosecone. Begad! If it doesn't fit, sand all t' parts t' make it fit. It needs t' slide in and out nicely. Avast, me proud beauty!

Get your 3 pieces o' glass cloth. Mix up some epoxy. Begad! Get a little paint brush. Brush on a coat o' resin on the face o' t' wings. Arrr! Place t' glass on t' face o' t' wings. Aye aye! Wet out t' glass so it disappears. Turn part over and repeat on strongback with two pieces o' glass. Arrr! Usin' t' brush in dabbin' motions, me hearties, stipple t' glass onto t' surface so all t' glass is in contact with t' balsaply. Blimey! This is easiest as t' resin begins t' set and becomes tacky. Try to eliminate all t' air bubbles. Allow t' cure t' B stage (this is when t' epoxy is kind o' rubbery) and trim t' glass to t' correct size. Avast, me proud beauty!

Find out where t' hole in t' panel clip lines up on t' retainer ring. Begad! They are all different so you have to fit and see. Arrr! Generally t' hole with t' clip in place is about 1/2" down from t' U bend in t' clip. Aye aye! Make a note where t' hole hits t' retainer ring. Begad! Ahoy! Install t' U-bolt at this time. Begad! Blimey!

Usin' t' shoulder o' t' NC as a guide, arrr, arrr, mark t' base o' t' nosecone on your airframe. Ahoy! Well, ya bilge rat, blow me down! Install t' payload section into t' NC. Install t' NC on t' airframe you intend t' use. Well, blow me down! Usin' t' mark you just made and your measurement o' t' panel clip on t' retainer rin' drill 4 holes 90 degrees from each other around t' airframe. Avast, me proud beauty! Ahoy! If they are nay dead on, t' airframe will only align with t' holes as drilled. Arrr! Ahoy! Make a mark on t' NC and on t' airframe where t' holes line up properly. Begad! Avast!

Remove t' nosecone. Aye aye! Ya scallywag! Remove t' payload section. Avast, me hearties, me proud beauty! Install t' panel clips. Ya scallywag! Begad! Reinstall t' nosecone. Reinstall the payload section. Install 4 #8 screws, T' nosecone ain't comin' off for nothin'. Aye aye! All t' parts are workin' together to keep t' electronics you install on t' board in place and in t' nosecone. Aye aye! Well, blow me down! T' U-bolt will take a major hit and will transfer t' load t' t' airframe through t' panel screws and retainer ring. You may have problems if you use some serious noseweight so take care. Begad! Deployment shock loads can be upwards o' 15 or 20 g's makin' a one pound noseweight suddenly equal t' a 20 pound noseweight. Ahoy! Ahoy!

Install some electronics, arrr, a power source, a shunt for your pyro, shiver me timbers, and go flying!

This nosecone flew with on a Binder Raptor on a J350. Arrr! Unfortunately t' motor ejection charge went early due t' an improper seal in t' forward closure delay well. (Pilot error) It was supposed t' be a long delay t' back up t' electronics but it be way short. Ahoy! Blimey! : ) T' charge went off while t' rocket was still boostin' but the thin' held together, t' chute deployed, shiver me timbers, shiver me timbers, and no damage be done.

Bob Fortune
© September 2000