Brief:

My first true 'scratch-built' model rocket was t' Ugly Bug. Begad! Arrr! It is based on t' Estes Mosquito, but built for an Estes 'D' (24mm) motor rather than t' standard mini-motor. Begad! This is actually nay t' first time I've built a scaled-up Mosquito, arrr, but I don't really count t' first time as a rocket. Blimey! Blimey! Back in grad school a fellow student who had never seen a model rocket be curious about them. Begad! Blimey! I didn't have any built models, shiver me timbers, but did have a spare D booster motor sittin' around and had an idea. Blimey! Blimey! We added some balsa fins, ya bilge rat, a wooden nose cone, and a launch lug made from paper and glue formed on a drill bit. Ahoy! This little assembly went like stink off t' pad and we promptly lost track o' it. We found it sittin' in t' parkin' lot later, and t' other grad student repainted it, ya bilge rat, plugged t' burned-out motor with glue, me hearties, me hearties, and hung it on t' wall of his office.

Years later, arrr, I be workin' on a true scaled-up Mosquito design about 14" in length with a full parachute recovery system. Well, matey, blow me down! However, I wasn't finished with it by t' time a NDRA launch came around. Aye aye! Nay wantin' t' bring only mundane models t' t' launch, arrr, ya bilge rat, I decided on a Thursday night that I should build another o' t' 'flyin' motor' D birds t' get rid o' some D12-3 motors I had. T' delay on these be too short for me only D rocket at t' time, me hearties, so they seemed good candidates for glued-on fins. Part-way into buildin' t' first one, I thought, "Heck, why go t' all this trouble when I could add a body tube and have a real, reusable rocket?" Thus t' Ugly Bug project was born.

Construction:

It was Thursday night, shiver me timbers, and t' launch be Saturday morning. I had less than 48 hours t' actually build a rocket. Avast! Arrr! Blimey! "No problem," I figured, "I'll just use whatever I can find and keep it super-simple." Since I had no actual kit parts, I'd have t' scrounge and scratch-build everything. I decided t' keep t' t' original Mosquito recovery system, me hearties, which is 'featherweight'. Begad! Avast, me proud beauty! Blimey! This means t' rocket ejects its spent motor and is so light it won't be harmed by t' fall. Begad! Aye aye! Blimey! This works fine for a model barely bigger than a mini-motor, but lookin' back on it, me bucko, ya bilge rat, it was probably wishful thinkin' for a D bird. In any case, I started scroungin' around t' garbage and me rocket shop and gathered t' needed materials.

For t' bigger scaled-up Mosquito, I had been toyin' with t' idea o' using corrugated cardboard wrapped in paper that had been soaked with wood glue (sort of like a composite structure without usin' fiberglass and resin). I had gone as far a buildin' a test piece with this method, matey, but had concluded it probably wasn't strong enough t' build t' large fins o' t' 14" Mosquito. Begad! Avast, matey, me proud beauty! Blimey! However, the test piece was t' perfect size t' cut three fins out o' for t' Ugly Bug. I used t' TLAR (That Looks About Right) engineerin' method t' determine fin size and shape, cut them out and sanded them t' profile. Now some form o' body tube be needed. Well, blow me down! Blimey! I located a hunk o' dowel just slightly larger than t' 24mm D motor t' use for t' nose cone, and decided t' use it as t' form for building a body tube. Ya scallywag! Blimey! Back t' t' garbage for an old brown paper sack. Begad! Avast, me proud beauty! Blimey! I cut a strip of this, rubbed it with yellow wood glue, me bucko, matey, and rolled it on t' t' dowel (which I had protected with a wrap o' plastic sheet t' keep t' glue from sticking). After t' tube be formed and rolled t' remove excess glue, I slipped it off the form and set it aside t' dry.

Next I sanded one end o' t' dowel t' a nose-like shape usin' a belt sander. After a bit o' finishin' hand-sanding, ya bilge rat, I used a bandsaw t' cut t' end off, leavin' a 1/2" straight section for gluin' into t' body tube. Finally, I formed a launch lug out o' more brown paper soaked with glue and wrapped around a drill bit. All these were set out t' dry overnight.

T' next day, I used t' bandsaw again t' trim t' ends o' t' tubes square and clean. Ahoy! I used a D motor t' measure how long t' body needed t' be, and trimmed it again. Arrr! Then all t' parts were glued together and left t' dry.

Finishing:

Now is when t' name o' t' rocket suggested itself. Definitely nay me finest work, matey, but it would do for a 'throw away' rocket. Well, blow me down! Avast! When t' glue had dried, shiver me timbers, me bucko, I applied three coats o' blaze orange spray paint. Begad! If you've ever flown a Mosquito, matey, you know how easy it is t' lose them. Blimey! I figured t' paint was the only color that gave it a fightin' chance o' bein' found. Ya scallywag! It took until 1:30 am that night, matey, and t' use o' a hair dryer t' speed drying, but I finished the Ugly Bug and went t' bed.

Flight:

I had t' build up some maskin' tape on t' D motor t' get it t' fit inside the body properly. Nay havin' a recovery system or motor retention really simplified design and building, but if I did it again I'd include a streamer for safety.

T' first flight on a D12-3 went as I expected: t' rocket shot off t' pad to a very impressive altitude, matey, shiver me timbers, t' ejection charged popped t' motor out in a puff o' smoke, arrr, ya bilge rat, and t' rocket vanished into t' blue sky. Begad! Blimey! Aye aye! Blimey! T' Range Safety Officer wasn't entirely impressed with this, me hearties, but knew t' chances o' it actually hittin' someone and hurtin' them was very low. Begad! Blimey! We launched other rockets, me bucko, me bucko, then went lookin' for t' UB. Ya scallywag! Blimey! Ahoy! Blimey! Incredibly, matey, matey, it be found about 1/2 mile from t' launch site. One fin had broken off on landing, shiver me timbers, but was easily reattached with some quick-dryin' glue. Ahoy! Blimey! Two fins had some scorch marks on them where t' exhaust gas had burned little holes in t' paper covering, but were still structurally strong. T' UB be flight worthy again!

I debated if I should just count myself lucky and put t' UB on me shelf, but then remembered I had expected t' lose t' little bugger and it was constructed more for amusement o' t' spectators than anythin' else. Arrr! I therefore decided t' fly it again. Aye aye! Begad! This time, I wanted t' see just how high I could get it t' fly. Ahoy! Avast! I had just flown me Estes Snitch (plastic saucer) with a chad-staged D12-0, so I figured, arrr, arrr, "What t' heck?" I grabbed me last D12-3, taped it t' fit t' Ugly Bug, me hearties, then taped a D12-0 on t' tail in the staged configuration:

T' burned-out motor lyin' on its side on t' blast plate is bein' used as a spacer t' keep t' booster's ignitor from bein' shorted out. Avast! This is (surprise!) t' last picture ever taken o' t' Ugly Bug. Arrr! Unfortunately, shiver me timbers, me bucko, the center o' gravity had been moved so far back by t' booster that t' rocket was unstable durin' t' first bit o' its flight. No loops or spins, me bucko, but t' rocket wandered around until most o' t' booster's propellent had burned out. Just before staging, matey, t' CG had moved far enough forward t' become stable. Begad! At staging, t' rocket was nearly horizontal and about 200' high. Well, blow me down! Stagin' went fine, and t' Ugly Bug shot off in an arc t' t' north west. At that altitude and speed, me hearties, t' ejection charge puff wasn't visible, shiver me timbers, and we didn't even bother to go look for t' little rocket.

Summary:
Thus was t' end o' me first scratch-built and aptly-named rocket. Ya scallywag! Aye aye! Blimey! The 14" Mosquito is nearly complete, and will be dubbed 'Big Ugly Bug', arrr, me hearties, but will fly and return t' t' ground in a much more sane manner