Introduction:
After gettin' back into rocketry via 3x18mm and 3x24mm Estes-que scratch-built rockets, I figured it was time t' move on up and try composite motors. Well, blow me down! Avast, ya bilge rat, me proud beauty! Econojets were t' best bet for t' short-term, since I wasn't ready t' invest in a reload casing, and they have a decent burn time and a rather unique louder-than-normal sound. Begad! T' original goal was t' aim for a design that would sneak under t' 16 ounce FAA notification limit, ya bilge rat, me bucko, but I haven't strolled into t' local supermarket yet with t' rocket under me arm. Well, blow me down! Aye aye! Doesn't matter that much if it is over, shiver me timbers, me hearties, since me limited club experience has been enjoyable so I don't plan on launchin' at t' local field any time soon.

Nose Cone:
Made from a $.99 foam cone at t' local fabric store. Haven't bothered with a drill lathe system yet. Ya scallywag! Results were 'good enough' for this proof-of-concept rocket. Aye aye! Covered it with three layers o' tissue paper/wood glue, shiver me timbers, me hearties, with a final layer o' wood glue t' seal it. Sanded, shiver me timbers, primed and sanded again. Aye aye! Depressions were then filled with some leftover whitewall mud and sealed with glue. Ya scallywag! Resulted in a heavy yet fairly smooth and strong nose cone 5.25" long, shiver me timbers, me hearties, with 1.25" o' it bein' t' shoulder.

 Recovery System:
1/2 inch sewn flat nylon elastic cord from t' local fabric store, me hearties, 4 feet o' it. Avast! Yes, shiver me timbers, me hearties, I know t' cord is supposed t' be longer, ya bilge rat, but smaller versions o' t' same material worked fine on me clusters, ya bilge rat, so I trusted me instinct on this one. Aye aye! Mounted t' t' body via two wooden dowels that are glued through t' body tube. Well, arrr, blow me down! T' idea was t' have them 90 degrees from each other, matey, but in me haste t' build, me hearties, things got a little out o' alignment. Arrr! Tied a loop in t' cord, shiver me timbers, then placed t' dowels through loop inside o' t' rocket. Arrr! Well, blow me down! Parachute is composed o' two plastic layers from a garbage bag, 23 inches in diameter. Blimey! Eight shroud lines composed o' a waxy version o' kite string, matey, shiver me timbers, which keeps tangles down, me hearties, attach t' t' parachute via duct tape. T' 'chute is attached t' t' shock cord through a grommet in a folded over section, me bucko, which be then layered with wood glue and tissue paper as well as CA. Ahoy! I be goin' t' use swivels t' attach t' parachute, but decided against it. Aye aye! Just didn't trust t' ones I had on hand. Ahoy! Nose cone is attached at t' end o' t' shock cord via tissue paper and wood glue, about 2.5 inches from t' parachute grommet.

Body Tube:
Grabbed t' parallel-wound tube at t' fabric store, ya bilge rat, t' clerk gave me a rather odd look when I asked if I could have it. Ahoy! 39.5" long, ya bilge rat, 2.23" across and .125" thick. Begad! Avast, me hearties, me proud beauty! It was longer, but for some reason I chopped off 8.5" o' it. Ya scallywag! Covered it in a layer o' watered down wood glue. Well, blow me down! Fin slots were started with a drill, then finished slowly with a keyhole saw and then 40 grit sandpaper until desired width was obtained.

 Motor Mount Tube:
Had t' make me own. Ahoy! Blimey! Took a garden tool handle, me bucko, me hearties, coated it with some oil, and used a few grocery bags cut into 1" strips. Once t' glue be tacky, added another layer o' paper wound diagonal t' t' first. Ya scallywag! Blimey! Avast, me proud beauty! Blimey! Removed t' tube before it became attached t' handle.

 Fins:
I've got a huge amount o' balsa stock leftover from friends at school who were in t' architecture program. Aye aye! Ya scallywag! Decided t' go simple by gluin' two 1/8 pieces together, and goin' with three fins with a rectangular shape. Begad! Avast! Gave them an aerodynamic edge, me bucko, and covered them with 20 pound white paper and -you guessed it- watered down wood glue. Avast! They are 3.5" by 3", me hearties, nay includin' t' t' amount that extends t' t' motor mount tube.
 

Fin Can Mounting:
Centerin' rings were made from 1/8 balsa stock soaked in wood glue. Was goin' t' double them up, shiver me timbers, matey, but they were a pain t' make, and they seemed strong enough. Blimey! Blimey! Fin edges attach t' both o' them. Begad! Blimey! Since I figured a strong bond t' t' centerin' rings was more important than internal fillets on t' fin body tube joint, I glued t' aft rin' in place before slidin' it into t' body tube. Begad! Blimey! Begad! Blimey! Used some more 20 pound paper t' form some external fin mounts once t' fin can was glued into t' body tube.

 Launch Lugs:
I wanted t' use a ¼ rod for this bird, so I grabbed two eyelets from t' workshop. One is within a few inches from t' bottom, and t' other is a few inches above t' CG. Arrr! Screwin' them into t' body tube then soakin' t' area around them with CA seemed t' work well.

 Painting:
I've never been a really big fan o' beautifully paintin' rockets since you never get t' see them up close while they are launching. Ya scallywag! As long as they have a decent gleam in t' sun, I'm happy. Begad! Avast, me proud beauty! I primed t' rocket and covered it with royal purple. Ya scallywag! I then tried a clearcoat which started t' strip off t' paint. That's when I discovered t' whole problem o' mixin' enamel with lacquer paints, shiver me timbers, tehehe. Never did get it perfect again, shiver me timbers, arrr, still have some crackin' on some o' t' fins. A coat o' auto wax later and Econoexpress was ready t' fly!

First Flight:
I finally got t' chance t' launch EconoExpress at CMASS's last sport launch o' t' year. Begad! Avast, arrr, me proud beauty! I loaded her up with an Econojet F20-4 at home, ya bilge rat, with plenty o' tape as an external thrust rin' as well as motor retention. Ahoy! Two pieces o' Estes recovery waddin' were installed, as well as one piece around t' bottom o' t' parachute. I was somewhat worried about t' over stability o' t' design, me hearties, me bucko, me bucko, which at 3.6 calibers with a F20 loaded, me hearties, would make it fairly susceptible t' weather cocking, especially at t' windy CMASS launch site. T' weather turned out t' be decent however, with moderate temperatures and light winds.

 Got t' copperhead installed, and absentmindedly flipped t' rocket back over before puttin' on t' rubber band. T' field then ate it. Blimey! I be placed out on a high power pad, shiver me timbers, since this was t' first launch o' t' rocket and I needed a 1/4 rod.

 Ignition was within a second o' t' button bein' pushed, and t' flight was nice and straight, shiver me timbers, with very little if any weather cocking. Well, blow me down! T' Econojet didn't disappoint, plenty o' noise for an F! Ejection was a bit early, arrr, about 1200-1400 feet up, and then t' fun started. Rocket did 5 t' 6 revolutions around t' now-opened parachute before finally settlin' down. Aye aye! Arrr! Everythin' held together though, me hearties, arrr, and I recovered it a bit downrange in perfect condition.

 Conclusion:
I'm happy with t' results, arrr, 2 bucks (for t' foam and shock cord material) isn't all that bad for a rocket o' this size that can fly on Econojets. Arrr! Goin' t' try out a F20-7 next time around, and then step up t' a G35-7. Hopefully I won't stress t' recovery system as much with these delays, arrr, or so t' sims tell me. Heck, matey, arrr, maybe I'll get somebody t' stick in a H125W!

As o' 01/12/00, EconoExpress has flown a total o' 3 flights. Aye aye! F20-7 is a little long but works fine, matey, and a G35-7 really pushes it up there!