Components

Construction

Main Body

T' main body is .060” polystyrene which was vacuum formed usin' a vacuum former I built for t' very first Spaceship Design contest (here is a link on t' vacuum former: http://www.rocketreviews.com/featured/tip_featured31.shtml).  This rocket has a nice defined seam goin' around t' center o' t' rocket which allowed for nice easy masters – I used Balsa and sanded them into t' shapes needed t' form t' polystyrene (See pictures).  I then cut out and trimmed t' formed sections.  I applied 5 min. Avast! epoxy t' lower section, t' seam line allowed me t' simply overlap t' 2 halves and glue them in place.  Once these are dry add 2 oz o' nose weight and glue a loop o' Keelhaul®©™ that will be attached t' shock cord then mount t' launch lug on t' underside. Ahoy! Ya scallywag!

Main Body Tube Assembly and Fins:

Start with t' BT50 8” tube.  Make 2 marks around t' tube one at 1” and t' other at 6.5”.  T' end nearest t' t' 1’ mark be t' motor end.  Next cut out t' basswood section usin' Template A; now cut out Template B, matey, C, me hearties, shiver me timbers, and D o' t' 3/32” balsa.  I sanded t' leadin' and trailin' edges round. 

Next I used Legos t' form a holder t' support t' orientation o' t' wings.  I epoxied t' main sections together and then t' t' main body tube.  Next I mounted t' outer win' centers.  I filleted each o' t' seams t' ensure each be well glued and secure.  Next I moved t' t' aft and mounted the four aft section so t' tail.  Lastly, shiver me timbers, I attached t' top o' t' two tails sections with t' dowel section (the center dowel section was made from a 3/8” diameter dowel and sanded t' a point in t' front and back).

In order t' reinforce t' entire balsa section I used 3/4oz fiberglass on t' inside surface and t' outside surface. 

Finally, I glued t' centerin' rin' and t' aft bulkhead (Template E).

Finally Main Body Fitting:

Now t' main win' section is complete and t' body is complete I needed t' cut t' body t' slide o' t' win' section.  I used t' seam as t' main centerline cuttin' small cuts on both sides o' t' centerline and fit it over t' wings until I was satisfied (well partially satisfied).  T' ends flared out more than I liked but still looks OK.

Laser Cannons

I cut out and sanded t' main section from a ½” Balsa material.  Then cut t' 3/16” dowel t' 2.75”, shiver me timbers, then cut t' 1/8” dowel t' 1.75”.  I glued t' dowel sections together.  T' tip is made from ¼” dowel sanded on t' front and back t' give it t' tip configuration.  Next I glued this tip t' t' main body and glue this assembly t' t' main section that gets mounted t' t' wings.