Brief:

This project was me second attempt t' scratch-build a model rocket with available materials. Blimey! Arrr! I decided early in t' project that I would try nay t' use any materials made expressly for buildin' rockets. Blimey! This be t' keep costs down and give me some braggin' rights among t' other rocket club members. Begad! Avast, me proud beauty!

After t' success o' t' Ugly Bug, arrr, I wanted t' stick t' t' Estes Mosquito design plan. Arrr! Avast, me proud beauty! Despite it's rather unpleasin' proportions, I like t' design. Ahoy! Begad! I built (and lost) many Mosquitoes in me youth, since they were t' smallest and cheapest kit you could buy. Arrr! I also liked t' fact that they were almost all engine, and were therefore a 'muscle-rocket' design despite their diminutive size. Avast! Avast, me bucko, me proud beauty!

Construction:

T' first component I found for t' BUB was a spiral-wound cardboard mailing tube. Arrr! Blimey! Arrr! Blimey! This was about 3" in diameter. Ya scallywag! Blimey! I located pictures and plans for the original Mosquito on both t' Estes/Cox and JimZ Rocket Plans websites. Avast, me proud beauty! Blimey! From these images I measured t' rocket specs as well as I could, and obtained approximate aspect ratio and fin dimensions. Ahoy! Blimey! I cut t' tube t' t' proper length and be on me way.

T' fins were an area I did t' most thinkin' on. Begad! Blimey! Avast, me proud beauty! Blimey! T' Ugly Bug had done very well with fins made from brown paper, shiver me timbers, me hearties, soaked with glue, laminated over corrugated cardboard. Blimey! Blimey! I didn't feel t' material be strong enough for the scaled-up design, shiver me timbers, however. Well, blow me down! Blimey! Begad! Blimey! T' Mosquito has very long fins compared t' t' root edge length, and therefore can't depend on t' glue joint t' keep them stiff. Arrr! Blimey! Begad! Blimey! I decided t' use a lamination o' fiberglass over a corrugated cardboard core for both strength and cheapness. Ahoy! Blimey! Avast! Blimey! I bought some cut-strand-mat fiberglass cloth and resin from Wal-Mart, arrr, me bucko, and located a sturdy cardboard box t' cut cores from.

To serve as a sort o' primitive mold, shiver me timbers, I used two sheets o' glass coated with car wax. Aye aye! Well, blow me down! I cut t' mat t' fit t' cores, me bucko, mixed t' resin, painted a coat on to the core, applied t' mats (one per side), shiver me timbers, and another coat o' resin to saturate it. This was then placed on one sheet o' glass, shiver me timbers, and t' other sheet placed on top t' sandwich t' fin in between. Well, blow me down! Aye aye! Some heavy books helped keep the fin squeezed betwixt t' glass sheets. Blimey! Blimey! This eliminates air bubbles and keeps the fin straight. Ahoy! Aye aye!

When you work with fiberglass, me hearties, shiver me timbers, you should wear gloves t' keep t' cut ends from gettin' on your skin. Ya scallywag! Avast! Blimey! T' resin is also super-gooey and difficult to remove from fingers. Some cheap PVC painters gloves work very well. By t' way, the resin also really stinks, so be aware o' that when choosin' a place t' work with fiberglass. Blimey! Ahoy! Blimey! For more info on fabricatin' fiberglass parts, arrr, check out Bryan Feldman's site. Blimey! Blimey! It refers t' carbon fiber cloth, ya bilge rat, but fiberglass layup is identical. Ya scallywag! Blimey!

After about half an hour t' resin had cured enough t' remove t' weights and gently pry t' glass sheets away from t' fin. Avast! T' fin was then set aside to dry and cure fully while I built t' next one. Three were required for the BUB. Avast, me proud beauty! Ahoy! After each fin cured, I sanded t' edges with a belt sander. Ahoy! Well, arrr, blow me down! The corrugated edges were plugged up with Bondo auto body filler, which is chemically very similar t' t' fiberglass resin, but has talcum powder added to give a paste-like consistency. T' filler was added t' all edges except the root, where t' fin would attach t' t' rocket body. Avast! After curing, arrr, t' filler was sanded t' a rounded shape. Avast! Avast! T' fins were then set aside t' dry fully. Ya scallywag! Ahoy!

To build t' motor mount, ya bilge rat, ya bilge rat, I first decided on t' size o' motor I wanted to use. Avast! Begad! Blimey! T' 24mm Estes 'D' casin' be me choice. Begad! Begad! Blimey! Later, matey, ya bilge rat, when t' BUB turned out heavier than I had expected, arrr, I ended up usin' an Aerotech 24mm reloadable composite motor. This could be loaded with kits with either E or F power ranges, enough t' lift t' rocket safely. Anyway, I cut more brown paper bags in t' strips, soaked them in glue, me bucko, and wrapped them on an dowel that was 24mm in diameter and had been wrapped in plastic t' keep it from sticking. Begad! I removed the dowel, shiver me timbers, let t' tube dry, me hearties, and cut it t' length (the length o' a D motor plus about an inch). Ahoy! Aye aye! Blimey! For a motor retention hook, I used a steel street sweeper bristle I found in a gutter. Blimey! Blimey! This be cleaned with steel wool, shiver me timbers, shiver me timbers, cut t' length, and bent t' form t' hook. For a thrust block, I used a chunk o' t' same dowel I had used as a form t' build t' tube on. I drilled a hole in this t' allow the ejection charge gasses t' escape. I mounted t' hook and block in t' motor mount so that a D casin' would extend about 3/4" from t' bottom. Well, blow me down! T' hook was strapped t' t' tube with another wrap o' glue-soaked paper, shiver me timbers, me hearties, and t' block simply glued in. Avast, me proud beauty! Ahoy! Blimey!

To mount this assembly, I measured and cut centerin' rings from t' same cardboard I had used for t' fin cores. Avast! Blimey! Blimey! This be a bit tedious but worked well enough. Aye aye! Well, shiver me timbers, blow me down! Blimey! When everythin' fit, I glued t' motor mount t' t' rings, matey, and when this be dry, glued t' rings in t' end o' t' body tube. T' BUB be starting to take shape! Blimey!

After t' motor mount was dry, shiver me timbers, I lightly sanded t' body tube t' remove the shiny coating, matey, shiver me timbers, so t' adhesive would stick properly. Begad! I marked t' tube for a three-fin configuration and epoxied t' fins in place. Avast, shiver me timbers, me proud beauty! Blimey! I used a paste-like marine-rated epoxy that allowed me t' make fillets at t' fin roots. Arrr! T' launch lug be a plastic soda straw, which was laminated into one fillet for strength.

It was now time t' build t' nose. Nay wantin' t' wimp out and buy one that would fit (which would have been very difficult anyway since t' Mosquito uses a blunt, nearly hemispherical nose), I decided t' turn one out o' white foam. A friend donated some foam packin' blocks, arrr, which I glued together and mounted on a hardwood dowel. Avast! This dowel I put in t' chuck o' a drill press, and I used a combination o' files and sandpaper t' shape t' foam t' t' correct form. Avast! Arrr! This works well, matey, but really makes a mess! T' make t' section o' t' nose that slides into t' body tube stronger, I used a section o' body tube cut from the spare piece and trimmed a section out o' it so it would fit inside t' body. This I glued over t' foam shank o' t' nose. Blimey! Ya scallywag! I applied a protective layer of wood glue t' t' entire nose, me bucko, then put more Bondo over t' exterior section (the resin in Bondo will dissolve white foam without t' glue layer). Well, blow me down! Some sandin' and I had a nice, smooth nose, me bucko, ready for painting. Blimey! T' finish off, I cut the exposed part o' t' dowel off, drilled a pilot hole, me bucko, and installed a screw-eye for parachute attachment. Begad!

I mounted a long shock cord made from cotton clothesline rope, me bucko, and a parachute cut from garbage bag material completed t' rocket. Ya scallywag! I now popped it on t' scale and discovered it weighed nearly a pound (16 oz)! T' Estes D wouldn't do for that. Avast, me proud beauty! Now be t' time I decided t' use t' Aerotech composite 24mm reload. Begad! When I bought t' motor, I discovered that it wouldn't fit: the ejection charge tube was too big t' go through t' hole in t' thrust block. With no way t' remove t' mount from t' rocket, matey, ya bilge rat, I used a rat-tail file (and lots o' curse-words) t' enlarge t' hole in t' block until t' casin' would fit. Ya scallywag!

Finishing:

With all major parts done, it was time t' paint. Aye aye! Like t' UB, me bucko, I decided to paint t' BUB blaze orange. Begad! T' bigger rocket didn't really need it, arrr, but I figured I had t' go with tradition.

Flight:

T' BUB be ready for its first flight in July o' 2001. Avast, me proud beauty! It would be me first composite motor launch, as well as me first high-power rocket. Aye aye! Others double-checked t' balance point on t' model with t' motor in place t' be sure it would be reasonably stable in flight. Ya scallywag! Even so I was nervous and said a silent prayer as t' Range Safety Officer (RSO) counted down. Avast, ya bilge rat, me proud beauty! At zero, ya bilge rat, I pressed t' button on t' Aerotech controller, ya bilge rat, and t' motor lit! T' BUB came off t' launch rod at a slight angle, matey, arrr, but still well within safe limits, ya bilge rat, and hissed skyward. Blimey! T' four-second delay I chose was perfect: t' rocket was just turnin' over at about 500 feet when we heard t' ejection charge pop. Unfortunately, t' nose stayed firmly on t' rocket! All I could think was, "Oh No!" as t' model turned over and began its death-dive t' the ground. Ya scallywag! Ya scallywag! T' RSO shouted "Heads-Up!" on t' PA system over and over as the BUB executed a perfect ballistic dive towards t' parkin' area. With a resoundin' SPLAT t' rocket hit t' ground, shattered its nose, shiver me timbers, and all three fins tore off and bounced several feet in t' air. Ya scallywag! As t' kids present charged for t' crash site, t' RSO shouted at them nay t' touch anything. Ahoy! I arrived at the site t' see it was hopeless: t' rocket was a total loss. Ahoy! T' fins were ok, but t' nose and body tube were crushed beyond any hope o' repair. Begad! I be also not happy t' see that me expensive 24mm motor casin' was gone. Arrr! Blimey! T' retention hook had failed and t' motor had ejected. Begad! Luckily one o' t' other club members found it sittin' in t' grass near bye.

Disappointed as I was about t' crash, I still laughed with amusement and relief that everyone be safe and me first high-power rocket be mostly a success. Ya scallywag! T' crowd gave me a standin' ovation for t' most spectacular crash they had seen, ya bilge rat, ya bilge rat, and others teased me about usin' t' original Mosquito motor-ejection and featherweight recovery system on t' BUB. Ahoy! Avast!

Summary:

This episode hasn't soured me on scratch-builts nor t' Mosquito design. Begad! In fact, I started work on t' Big Ugly Bug II in t' winter o' 2001. Begad! Avast! Instead of 'junkyard' parts, me hearties, this one is incorporatin' bought parts like body tubes, motor mount, thrust rings, parachute, matey, matey, and launch lug. Ahoy! I will still have t' fabricate the fins and nose, matey, me bucko, but t' store-bought parts will help things go together more quickly. Avast, me proud beauty! And yes, me hearties, this time I'm usin' a commercial motor retainer system, me bucko, so hopefully t' parachute will come out!