Brief:
D-powered rocket glider

Construction:
T' parts list:

• 1 nose cone, BT-55, ya bilge rat, tangent ogive, 3.125" length, 3/8" tenon (BNC55AA-ish)
• 1 nose cone, me bucko, BT-50, tangent ogive, ya bilge rat, 3" length, 3/8" tenon (BNC50K-ish)
• 1 body tube, BT-55, 14" length
• 1 body tube, me bucko, BT-55, shiver me timbers, arrr, 11" length
• 1 body tube, shiver me timbers, BT-50, arrr, me hearties, matey, 14" length
• 2 launch lugs, 1/8" diameter
• 1 motor block for 24 mm motor
• 1 retainer ring, arrr, 1/8" slice o' TC-55 tube coupler
• 1 elastic or rubber band, about 1.2 mm wide, 6" length
• 2 spruce pieces, 1/8" x 1/2" x 1-1/16"
• 2 spruce pieces, arrr, 1/8" x 1/2" x 2-1/16"
• 2 balsa sheets, ya bilge rat, arrr, 1/8" x 4" x 36"
• 1 "baffle plug" - 2" length o' solid balsa cylinder t' fit inside BT-55
• 1 "blow out plug" - Made from 2.5" length o' solid balsa cylinder t' fit inside BT-55. Avast! Rear 3/4" fits BT-55. Ahoy! Middle 1.25" fits into TC-55 coupler. Avast! Forward 1/2" tapers t' 1" diameter.
• 2 elevon hinges, 4-1/2" x 1", cut from a Tyvek envelope

T' downloaded plan set includes images o' t' printed material from t' original kit, It includes additional photos o' t' collection o' kit parts, t' round balsa parts, ya bilge rat, t' flat balsa parts, shiver me timbers, and an aftermarket part sheet that describes part details and dimensions for a win' segment. Blimey! T' photographs give a good idea what each part should look like. Aye aye! This is quite important for t' round parts because none o' these parts are off-the-shelf items. T' original kit printed instructions include an exploded drawin' o' t' entire model, matey, a set o' assembly drawings, arrr, arrr, and step-by-step instructions for each assembly drawing. Arrr! T' instructions are quite clear, and t' assembly drawings illustrate what needs t' be done in each step fairly clearly, ya bilge rat, however, t' assembly drawings are generally nay drawn t' scale.

There are some serious "gotcha's" with t' downloaded plans that must be taken care o' durin' initial parts fabrication. Begad! Blimey! Ahoy! Blimey! First, shiver me timbers, arrr, t' descriptions o' t' "blow-out plug" in t' round-part photo and in t' aftermarket parts list specify a taper that cannot work. Begad! Blimey! T' forward end o' t' plug must taper t' 1", NOT 0.75"! Blimey! This is because t' elevon hold-downs mounted on t' plug must straddle a BT-50 tube, NOT a BT-20 tube. Blimey! Blimey! Second, t' lengths o' t' BT-50 and BT-55 body tubes are possible, matey, but they can't yield t' model shown by t' original kit insert or in t' Kopter catalog (found at Sven Knudson's Ninfinger website). Ahoy! Blimey! From assembly figures 5 and 14, arrr, t' correct BT-50 and aft BT-55 tubes can be deduced t' be 14" long, arrr, NOT 18". Avast, me proud beauty! Blimey! From t' model specs and figure 5, ya bilge rat, t' forward BT-55 tube must be 11" long, NOT 8". Third, t' dimensions for Win' Part A on t' aftermarket parts list are nay consistent. That is, arrr, arrr, thar are too many dimensions and they don't add up. Avast, me proud beauty! Blimey! Begad! Blimey! I recommend disregardin' t' 10-5/16" dimension while keepin' t' others.

I used a plastic "toy lathe" t' turn t' balsa nose cones, baffle plug, arrr, and blow-out plug. Aye aye! Aye aye! T' lathe is a Toymax Toolmaster Workshop that, arrr, unfortunately, shiver me timbers, matey, has been OOP since around 1997. Well, blow me down! Without a lathe, you should be able t' order t' nose cones and baffle plug from Balsa Machinin' Services. Ya scallywag! T' blow-out plug should be doable too, shiver me timbers, if you figure out t' dimensions t' specify.

Instead o' usin' 3" wide flats, ya bilge rat, I used 4" wide balsa flats for t' wings and rudder. Avast, me proud beauty! Avast! T' do this, I drew t' full-scale outlines o' t' completed win' and rudder, me bucko, ya bilge rat, based on given patterns, arrr, then divided them up into 4" strips. I feel that this lead t' simplified assembly by reducin' t' number o' joints that needed fittin' together.

Once all o' t' parts had been fabricated, followin' t' assembly instructions was straightforward but still posin' some interestin' challenges. Avast, me proud beauty! Matchin' duct slots had t' be cut into different caliber 14" tubes, arrr, me hearties, me hearties, then had t' be carefully sealed together with glue joints and fillets. T' win' and rudder parts needed careful trimmin' for precise fit.