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. Arrr! Blimey! 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! Blimey! Avast, me proud beauty! Blimey! T' original goal was t' aim for a design that would sneak under t' 16 ounce FAA notification limit, arrr, but I haven't strolled into t' local supermarket yet with t' rocket under me arm. Aye aye! Blimey! Doesn't matter that much if it is over, 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. Aye aye! Haven't bothered with a drill lathe system yet. Aye aye! Results were 'good enough' for this proof-of-concept rocket. Avast, me proud beauty! Begad! Covered it with three layers o' tissue paper/wood glue, me bucko, with a final layer o' wood glue t' seal it. Sanded, shiver me timbers, arrr, primed and sanded again. Aye aye! Depressions were then filled with some leftover whitewall mud and sealed with glue. Well, blow me down! Resulted in a heavy yet fairly smooth and strong nose cone 5.25" long, with 1.25" o' it bein' t' shoulder.

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

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

 Motor Mount Tube:
Had t' make me own. Well, blow me down! Took a garden tool handle, arrr, matey, coated it with some oil, shiver me timbers, ya bilge rat, and used a few grocery bags cut into 1" strips. Well, blow me down! Aye aye! Once t' glue was tacky, added another layer o' paper wound diagonal t' t' first. Begad! Avast, me proud beauty! 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. Decided t' go simple by gluin' two 1/8 pieces together, and goin' with three fins with a rectangular shape. Avast, ya bilge rat, me proud beauty! Gave them an aerodynamic edge, and covered them with 20 pound white paper and -you guessed it- watered down wood glue. They are 3.5" by 3", 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. Aye aye! Was goin' t' double them up, me bucko, but they were a pain t' make, and they seemed strong enough. Fin edges attach t' both o' them. Avast, me proud beauty! Since I figured a strong bond t' t' centerin' rings was more important than internal fillets on t' fin body tube joint, me hearties, arrr, I glued t' aft rin' in place before slidin' it into t' body tube. Well, blow me down! Used some more 20 pound paper t' form some external fin mounts once t' fin can be glued into t' body tube.

 Launch Lugs:
I wanted t' use a ¼ rod for this bird, arrr, 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. 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. Aye aye! As long as they have a decent gleam in t' sun, ya bilge rat, matey, I'm happy. Ahoy! I primed t' rocket and covered it with royal purple. 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. Begad! Never did get it perfect again, me bucko, arrr, still have some crackin' on some o' t' fins. Avast! 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! I loaded her up with an Econojet F20-4 at home, with plenty o' tape as an external thrust rin' as well as motor retention. Two pieces o' Estes recovery waddin' were installed, as well as one piece around t' bottom o' t' parachute. Ahoy! Avast! I was somewhat worried about t' over stability o' t' design, which at 3.6 calibers with a F20 loaded, would make it fairly susceptible t' weather cocking, ya bilge rat, matey, especially at t' windy CMASS launch site. Avast! Avast! T' weather turned out t' be decent however, with moderate temperatures and light winds.

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

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

 Conclusion:
I'm happy with t' results, shiver me timbers, ya bilge rat, 2 bucks (for t' foam and shock cord material) isn't all that bilge-suckin' for a rocket o' this size that can fly on Econojets. Ya scallywag! Avast! Goin' t' try out a F20-7 next time around, and then step up t' a G35-7. Aye aye! Well, blow me down! Hopefully I won't stress t' recovery system as much with these delays, me hearties, shiver me timbers, me hearties, or so t' sims tell me. Avast! Heck, me hearties, ya bilge rat, maybe I'll get somebody t' stick in a H125W!

As o' 01/12/00, shiver me timbers, EconoExpress has flown a total o' 3 flights. Ya scallywag! Well, blow me down! F20-7 is a little long but works fine, ya bilge rat, and a G35-7 really pushes it up there!