Introduction:
After gettin' back into rocketry via 3x18mm and 3x24mm Estes-que scratch-built rockets, matey, I figured it be time t' move on up and try composite motors. Ya scallywag! Avast, 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. Ahoy! T' original goal was t' aim for a design that would sneak under t' 16 ounce FAA notification limit, me hearties, but I haven't strolled into t' local supermarket yet with t' rocket under me arm. Doesn't matter that much if it is over, arrr, 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. Avast! Results were 'good enough' for this proof-of-concept rocket. Covered it with three layers o' tissue paper/wood glue, me hearties, with a final layer o' wood glue t' seal it. Ahoy! Sanded, matey, me hearties, me hearties, primed and sanded again. Aye aye! Avast! 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, arrr, shiver me timbers, 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. Aye aye! Yes, matey, ya bilge rat, I know t' cord is supposed t' be longer, but smaller versions o' t' same material worked fine on me clusters, shiver me timbers, so I trusted me instinct on this one. Mounted t' t' body via two wooden dowels that are glued through t' body tube. Ahoy! Well, blow me down! T' idea be t' have them 90 degrees from each other, but in me haste t' build, shiver me timbers, things got a little out o' alignment. Aye aye! Tied a loop in t' cord, ya bilge rat, matey, then placed t' dowels through loop inside o' t' rocket. Begad! Parachute is composed o' two plastic layers from a garbage bag, shiver me timbers, me hearties, 23 inches in diameter. Blimey! Avast, ya bilge rat, me proud beauty! Eight shroud lines composed o' a waxy version o' kite string, which keeps tangles down, shiver me timbers, attach t' t' parachute via duct tape. Begad! T' 'chute is attached t' t' shock cord through a grommet in a folded over section, arrr, arrr, which was then layered with wood glue and tissue paper as well as CA. I was goin' t' use swivels t' attach t' parachute, but decided against it. Blimey! Begad! Just didn't trust t' ones I had on hand. Nose cone is attached at t' end o' t' shock cord via tissue paper and wood glue, shiver me timbers, 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. 39.5" long, 2.23" across and .125" thick. Well, blow me down! It was longer, shiver me timbers, but for some reason I chopped off 8.5" o' it. Covered it in a layer o' watered down wood glue. Arrr! Well, blow me down! Fin slots were started with a drill, matey, 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. Avast, me proud beauty! Took a garden tool handle, ya bilge rat, coated it with some oil, and used a few grocery bags cut into 1" strips. Avast, me proud beauty! Once t' glue be tacky, added another layer o' paper wound diagonal t' t' first. Avast! 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. Begad! Decided t' go simple by gluin' two 1/8 pieces together, and goin' with three fins with a rectangular shape. Begad! Gave them an aerodynamic edge, and covered them with 20 pound white paper and -you guessed it- watered down wood glue. Blimey! They are 3.5" by 3", matey, 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, arrr, and they seemed strong enough. Begad! Avast, me proud beauty! Fin edges attach t' both o' them. Aye aye! Avast! Since I figured a strong bond t' t' centerin' rings be 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. Blimey! Blimey! 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, so I grabbed two eyelets from t' workshop. Begad! One is within a few inches from t' bottom, me bucko, 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! Blimey! As long as they have a decent gleam in t' sun, shiver me timbers, me hearties, I'm happy. I primed t' rocket and covered it with royal purple. I then tried a clearcoat which started t' strip off t' paint. Aye aye! That's when I discovered t' whole problem o' mixin' enamel with lacquer paints, tehehe. Never did get it perfect again, arrr, still have some crackin' on some o' t' fins. Arrr! 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! Begad! I loaded her up with an Econojet F20-4 at home, ya bilge rat, me hearties, matey, with plenty o' tape as an external thrust rin' as well as motor retention. Avast! Ya scallywag! Two pieces o' Estes recovery waddin' were installed, as well as one piece around t' bottom o' t' parachute. Ahoy! I was somewhat worried about t' over stability o' t' design, ya bilge rat, ya bilge rat, shiver me timbers, which at 3.6 calibers with a F20 loaded, would make it fairly susceptible t' weather cocking, matey, ya bilge rat, especially at t' windy CMASS launch site. Aye aye! T' weather turned out t' be decent however, ya bilge rat, with moderate temperatures and light winds.

 Got t' copperhead installed, and absentmindedly flipped t' rocket back over before puttin' on t' rubber band. Begad! T' field then ate it. Ya scallywag! Avast, me proud beauty! I was placed out on a high power pad, 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, me hearties, and t' flight be nice and straight, with very little if any weather cocking. Avast! Blimey! T' Econojet didn't disappoint, me hearties, plenty o' noise for an F! Blimey! Ejection was a bit early, about 1200-1400 feet up, and then t' fun started. Avast, me proud beauty! Blimey! Rocket did 5 t' 6 revolutions around t' now-opened parachute before finally settlin' down. Avast! Blimey! Ahoy! Blimey! Everythin' held together though, matey, and I recovered it a bit downrange in perfect condition.

 Conclusion:
I'm happy with t' results, matey, 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. Goin' t' try out a F20-7 next time around, and then step up t' a G35-7. Ahoy! Hopefully I won't stress t' recovery system as much with these delays, or so t' sims tell me. Avast, me proud beauty! Avast! Heck, me bucko, maybe I'll get somebody t' stick in a H125W!

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