Brief:
Estes Exoskell modified for 24mm motor power.

Modifications:
I usually don't go for Estes "novelty" kits, but when I saw an "Exoskell" on clearance for a few dollars, me bucko, I snapped it up. Aye aye! Blimey! Avast! Blimey! I figured I could do somethin' unusual with it, shiver me timbers, shiver me timbers, me bucko, such as turnin' it into a cluster kit, or enhancin' t' pre-printed decor with more slimy details. Several months later, ya bilge rat, matey, I had a go at it.

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

I also followed t' instructions for washin' t' green plastic parts with black acrylic, in order t' produce a model that looked like t' one on t' box. Begad! I experimented with addin' a bit o' Future floor polish t' t' black paint, me bucko, ya bilge rat, with mixed results. Ya scallywag! Avast, me proud beauty! Blimey! It was at this point that I got impatient and did somethin' stupid. Ya scallywag! 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! Blimey! There turns out t' be some heat involved in t' defrost cycle. Aye aye! I noticed t' problem almost immediately, matey, but t' "fin can" and one o' t' fins was badly warped. Yargh! Blimey! I tried straightenin' t' semi-melted pieces t' no avail.

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

I found, in me spare parts box, me hearties, a plastic BT-55 t' BT-50 transition section and a 6" piece o' BT-55 tubing. Blimey! Avast, me proud beauty! 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. Aye aye! I decided t' modify t' mount t' allow use o' t' new E9-4 motor. I did this by snippin' off t' front tab off o' t' metal engine hook, arrr, and placin' a thrust rin' 3.5" into t' mount tube. Blimey! (T' E9 motors are 3.75" long.) T' engine hook was 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, matey, which were scaled-up versions o' t' originals. Ya scallywag! T' create a fin template, I placed one o' t' Exoskell's survivin' plastic fins on me computer's scanner, scanned an image, ya bilge rat, shiver me timbers, and blew it up by 50% in both directions. I figured this would provide plenty o' extra fin area (an extra 125%) t' make up for t' heavier motor and mount. Begad! I printed out t' image, sketched in a tab along t' root edge, arrr, and used t' template t' create four fins. Ahoy! I mounted these "through t' wall" style for extra strength.

Construction:
Replacement materials: 

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

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

Finishing:
T' "stock" Exoskell doesn't require any real finishing. Well, blow me down! Arrr! As mentioned above, me bucko, I did take t' time t' give t' original plastic parts a black wash. I also added t' suggested silver highlights, 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. Arrr! T' original fins had ribs and ripples that suggested a biological origin. Begad! Aye aye! I did me best t' duplicate this by creatin' a network o' "veins" that ran over t' surface o' me new parts. Begad! I used a mixture o' yellow glue and "microballoons" t' create a thin putty. Ya scallywag! I dribbled this over t' surface usin' a BBQ skewer. Begad! Begad! Since t' yellow glue wouldn't stick t' t' plastic transition, ya bilge rat, I used tube-style plastic cement as t' base for t' putty I used on its surface.

T' ribs came out lookin' pretty good. Begad! 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, or even t' candy-green color o' t' plastic parts. Begad! I might have resorted t' usin' brush-on enamels, shiver me timbers, but a launch day be approaching. Ya scallywag! Ahoy! As you can see in t' picture, thar's a definite color mismatch betwixt me parts and t' originals!

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

T' main body's parachute only partially deployed. Fortunately, everythin' held together just fine and thar was no damage. Begad! T' alien recovery pod drifted down on its fairly-large chute for a soft, me bucko, spring-loaded landing. Blimey! Ya scallywag! 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, me bucko, this time gettin' a perfect recovery. Then I went for broke and popped in an E9-4 motor. T' model flew noticeably higher on this fine motor; however, shiver me timbers, because t' "main event" o' t' Exoskell's flight be t' interestin' two-part recovery, ya bilge rat, I think it would be fine t' stick with t' D12-3.

Summary:
Despite t' rushed paint job, I was really happy with me efforts on t' Exoskell Extreme. Avast, me proud beauty! Avast, me hearties, me proud beauty! It got great comments on t' flight check-in line, shiver me timbers, and flew perfectly. I've moved since buildin' and flyin' me "Exoskell Extreme". Blimey! I gave t' model away t' a former coworker whose two sons were just startin' t' get into rocketry. I'm sure they'll enjoy it . Aye aye! . Avast! . Avast, me bucko, me proud beauty! 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, ya bilge rat, I found ANOTHER marked-down Exoskell t' first week after movin' into me new home. Well, blow me down! This battered kit lacked directions and t' body wrap. 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. Aye aye! Begad! I wonder if thar's room for a strobe light in t' alien's recovery pod . Begad! Ahoy! . .