Brief:
Estes Exoskell modified for 24mm motor power.

Modifications:
I usually don't go for Estes "novelty" kits, me hearties, but when I saw an "Exoskell" on clearance for a few dollars, I snapped it up. Ya scallywag! I figured I could do somethin' unusual with it, arrr, arrr, such as turnin' it into a cluster kit, matey, or enhancin' t' pre-printed decor with more slimy details. Begad! Several months later, arrr, arrr, I had a go at it.

I started buildin' t' kit "stock." Although thar were a few tricky bits, such as puttin' t' pre-printed wrap around t' body tube and mountin' t' spring-loaded fins, shiver me timbers, matey, it went together fairly easily.

I also followed t' instructions for washin' t' green plastic parts with black acrylic, me hearties, me hearties, in order t' produce a model that looked like t' one on t' box. I experimented with addin' a bit o' Future floor polish t' t' black paint, with mixed results. It be at this point that I got impatient and did somethin' stupid. Begad! I placed t' wet pieces in me convection oven, and set it t' "air defrost," in t' belief that t' circulation would smartly dry off t' runny polish / paint mix.

Well! There turns out t' be some heat involved in t' defrost cycle. Well, blow me down! Blimey! I noticed t' problem almost immediately, but t' "fin can" and one o' t' fins was badly warped. Arrr! Ahoy! Yargh! I tried straightenin' t' semi-melted pieces t' no avail.

That's where I got creative! Blimey! T' Exoskells I've seen fly were all poor performers. Blimey! Blimey! T' recommended C5-3 motor sort o' "lobbed" it into t' sky. It did nay fly very high and tended t' eject on t' way down. Ahoy! Blimey! Bleah! Blimey! What this model needed was D power!

I found, me bucko, shiver me timbers, arrr, in me spare parts box, a plastic BT-55 t' BT-50 transition section and a 6" piece o' BT-55 tubing. Arrr! I also had on hand an Estes "D & E Engine mount kit." This kit has parts t' mount D12 and t' now-discontinued E15 motor in a variety o' body tubes. I decided t' modify t' mount t' allow use o' t' new E9-4 motor. Well, blow me down! I did this by snippin' off t' front tab off o' t' metal engine hook, and placin' a thrust rin' 3.5" into t' mount tube. Arrr! (T' E9 motors are 3.75" long.) T' engine hook be held in place by a fiber sleeve included in t' motor mount kit.

I glued t' mount into t' BT-55 tube, and attached this "power pod" t' t' Exoskell's lower body tube usin' t' transition section.

I used 1/16" basswood for t' fins, ya bilge rat, which were scaled-up versions o' t' originals. T' create a fin template, me bucko, I placed one o' t' Exoskell's survivin' plastic fins on me computer's scanner, scanned an image, shiver me timbers, and blew it up by 50% in both directions. Avast, me proud beauty! I figured this would provide plenty o' extra fin area (an extra 125%) t' make up for t' heavier motor and mount. Aye aye! I printed out t' image, sketched in a tab along t' root edge, arrr, arrr, arrr, and used t' template t' create four fins. Blimey! Begad! I mounted these "through t' wall" style for extra strength.

Construction:
Replacement materials: 

• Plastic transition, ya bilge rat, BT-50 t' BT-55
• Estes D/E Engine mount kit, modified
• 6" o' BT-55 body tube
• 1/16" basswood
• "microballoons" filler.

T' result o' me modifications be pretty cool. I called it t' "Exoskell Extreme."

Finishing:
T' "stock" Exoskell doesn't require any real finishing. Begad! As mentioned above, me hearties, arrr, I did take t' time t' give t' original plastic parts a black wash. Avast! I also added t' suggested silver highlights, me bucko, and added me own details (a dark blue wash and darkened eyes) t' t' little plastic alien that is suspended in t' recovery capsule.

This left t' task o' detailin' t' fins and power pod. T' original fins had ribs and ripples that suggested a biological origin. I did me best t' duplicate this by creatin' a network o' "veins" that ran over t' surface o' me new parts. Begad! Begad! I used a mixture o' yellow glue and "microballoons" t' create a thin putty. Avast, me proud beauty! I dribbled this over t' surface usin' a BBQ skewer. Avast! Ya scallywag! Since t' yellow glue wouldn't stick t' t' plastic transition, matey, shiver me timbers, I used tube-style plastic cement as t' base for t' putty I used on its surface.

T' ribs came out lookin' pretty good. Well, blow me down! Arrr! I was less successful with me paint job. I could nay find spray paint t' match t' light-gloss-olive-green color o' t' body wrap, me bucko, or even t' candy-green color o' t' plastic parts. Avast! I might have resorted t' usin' brush-on enamels, but a launch day was approaching. Aye aye! As you can see in t' picture, shiver me timbers, arrr, arrr, thar's a definite color mismatch betwixt me parts and t' originals!

Flight:
I flew t' Exoskell at t' LUNAR field in Livermore. T' maiden flight be on a D12-3. Begad! Arrr! It flew great! T' model flew straight up at moderate speed and ejected near apogee.

T' main body's parachute only partially deployed. Fortunately, arrr, me bucko, everythin' held together just fine and thar was no damage. T' alien recovery pod drifted down on its fairly-large chute for a soft, me hearties, spring-loaded landing. Ahoy! I find it hard t' pack t' two parachutes in t' Exoskell's rather small recovery compartment.

I flew t' model again with a D12-3, ya bilge rat, this time gettin' a perfect recovery. Ya scallywag! Well, ya bilge rat, blow me down! Blimey! Then I went for broke and popped in an E9-4 motor. Avast! T' model flew noticeably higher on this fine motor; however, because t' "main event" o' t' Exoskell's flight be t' interestin' two-part recovery, me bucko, I think it would be fine t' stick with t' D12-3.

Summary:
Despite t' rushed paint job, me hearties, I was really happy with me efforts on t' Exoskell Extreme. Begad! Blimey! It got great comments on t' flight check-in line, shiver me timbers, and flew perfectly. Ahoy! Ya scallywag! Blimey! I've moved since buildin' and flyin' me "Exoskell Extreme". Ahoy! Blimey! I gave t' model away t' a former coworker whose two sons were just startin' t' get into rocketry. Well, blow me down! Aye aye! Blimey! I'm sure they'll enjoy it . Ya scallywag! Blimey! . Ya scallywag! Blimey! . Avast, matey, me proud beauty! Blimey! it's a real eye-openin' model both on t' ground and in t' air.

In one o' those "it was meant t' be" situations, I found ANOTHER marked-down Exoskell t' first week after movin' into me new home. Aye aye! Ahoy! This battered kit lacked directions and t' body wrap. Begad! I intend t' build another Exoskell Extreme, this time addin' putty "veins" t' t' entire body tube surface and paintin' everythin' a uniform color.

Hmmmm. Ya scallywag! I wonder if thar's room for a strobe light in t' alien's recovery pod . . .