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. Begad! There are 1" square boxes on each template t' indicate correct sizing, me hearties, you may have t' fiddle with your printer output t' get t' correct size. Ya scallywag! These are .gif images.

Once you have t' templates sized and printed cut them out and match t' two halves t' t' match line shown. Aye aye! Blimey! 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. Avast! My design only has t' last 6" or so o' t' cone interior as payload. Arrr! T' lines are thar so you can cut to size as you choose. Begad!

Usin' a spray mount adhesive, me hearties, glue t' template t' t' balsaply. Arrr! Ya scallywag! Cut t' template t' rough shape. Usin' a sander or rasp or whatever, sand t' template t' it's final shape. Arrr! Avast, shiver me timbers, me proud beauty! 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. Ahoy! While you have this template cut your fiberglass cloth to fit, you need one piece this size. Aye aye! Begad! Once you have t' balsaply cut t' size, cut along t' dotted line. Avast! This is where the dowel goes. Ahoy! Aye aye! These two parts I am callin' "wings" for t' sake o' clarity. Aye aye! Take one win' and use it as a template t' cut an additional wing. Aye aye! 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, but a bit oversize - maybe an inch wider. Ahoy! Set t' glass aside for later use. Well, blow me down!

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

I made t' dowel poke out t' tip o' t' nosecone because it be fun t' do. Avast, me proud beauty! It's nay critical, shiver me timbers, you can simply make t' dowel shorter. Ya scallywag! 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, me bucko, whack off t' tip o' it so a 3/8" hole is developed. Blimey! Well, ya bilge rat, blow me down! 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, me hearties, shiver me timbers, take your time. Aye aye!

Fit t' dowel into t' NC so an inch or so protrudes from t' tip. Blimey! Avast! 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. Blimey! Aye aye! T' dowel is now square t' the NC if you trimmed t' tip properly. Arrr! CA t' dowel t' t' bulkhead and remove by pullin' on t' dowel protrudin' from the bulkhead. Begad! 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. T' two wings in t' same plane are flush with t' tangent o' t' dowel cross section. Well, blow me down! T' third win' is at 90 degrees t' these wings. Avast, me proud beauty! Let dry. Begad!

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

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

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

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

Usin' t' shoulder o' t' NC as a guide, me hearties, mark t' base o' t' nosecone on your airframe. Avast, me proud beauty! Blimey! Install t' payload section into t' NC. Install t' NC on t' airframe you intend t' use. Ya scallywag! 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. Aye aye! Blimey! If they are nay dead on, t' airframe will only align with t' holes as drilled. Make a mark on t' NC and on t' airframe where t' holes line up properly. Ya scallywag! Avast, me proud beauty!

Remove t' nosecone. Begad! Remove t' payload section. Install t' panel clips. Well, blow me down! Reinstall t' nosecone. Ya scallywag! Reinstall the payload section. Install 4 #8 screws, me hearties, ya bilge rat, T' nosecone ain't comin' off for nothin'. All t' parts are workin' together to keep t' electronics you install on t' board in place and in t' nosecone. Avast! Arrr! T' U-bolt will take a major hit and will transfer t' load t' t' airframe through t' panel screws and retainer ring. Ahoy! Arrr! 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!

Install some electronics, a power source, a shunt for your pyro, ya bilge rat, and go flying!

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

Bob Fortune
© September 2000