Brief:
Since I was a kid, I have always been captivated by t' paper shrouded rockets like "T' Point". My biggest nemesis, however, arrr, me bucko, was always t' Centuri Vulcan. Well, blow me down! I built lots o' them but never got one t' behave or even look very good...until I became a BAR and cloned one. Begad! It's nay t' best flier in t' world, but it actually works which is more than I can say about any that I built in t' '70s.

Recently, I have been in contact with Blades from TRF about his 24mm upscale and he kindly sent me t' PDFs for t' shrouds. After some conversation, we mentioned other scales and I mentioned that I used t' be an engineer and still had a color plotter that handles media up t' 5 feet wide and 300 feet long. Begad! This also means no splicin' o' t' shrouds!

I tried t' print first on a sheet o' posterboard, but t' plotter did nay like that. Ahoy! Blimey! T' media be too thick. I visited t' local paper distributor and found 130# cardstock that was less expensive, shiver me timbers, bigger, thinner, ya bilge rat, ya bilge rat, and stronger than t' posterboard. Begad! Blimey! I ordered some sheets and resolved t' give it a try.

It took some trial and error, but I found that landscape orientation would actually work.

Construction:
T' parts list:

• 2 sheets o' 26" x 40" 130# cardstock
• BT-60 x 18" tube
• 3-1/4" x 6" launch lugs
• piece o' typin' paper
• piece o' 1/4"x6"x6" balsa
• BT-60 Nosecone o' choice
• Cygnus 29mm t' BT-60 motor mount
• FlisKits BAF60 Baffle

After printin' out t' shrouds, shiver me timbers, shiver me timbers, t' first step in construction was t' cut out t' cardstock pieces. I cut t' body shroud right on t' lines and then rolled it up and kept it that way with some rubber bands so that I would have an easier time rollin' t' body later. T' other pieces were nay cut so close. Arrr! Well, blow me down! I wanted t' leave t' fold lines visible so that I could pre-fold them before doin' t' final cutting.

For t' 2 wings, t' tail, me hearties, and t' airscoop, I used a ruler t' fold along t' centerlines and make sure t' creases were sharp and straight. Blimey! T' ruler be then used t' fold under t' mountin' tabs. Begad! Well, blow me down! Blimey! Only then was t' excess material cut away.

Like t' original, me bucko, this Vulcan has a choice betwixt 2 different style cockpits. Avast, me proud beauty! One is simpler t' construct than t' other but t' more difficult one is reputedly more in keepin' with t' overall design. Ahoy! I like both cockpits. Avast! On one o' me normal size clones, shiver me timbers, I put both on and called it t' Vulcan Trainer. Aye aye! Avast, me proud beauty! I may do t' same with this one but for now, I went ahead and constructed both.

T' cockpits were pre-folded and then cut out. Avast, me proud beauty! White glue be used t' fasten t' tabs and produce t' 3D cockpits.

T' aft bulkhead was cut out and then a circle cutter was used t' remove t' center circle. Arrr! Ahoy! T' outline was then traced onto a piece o' 1/4" x 6" x 36" balsa.

T' rubber bands were removed from around t' body shroud and it was test fit around a BT-60 tube. Well, blow me down! It fit just right. Well, blow me down! Ya scallywag! Blimey! An extremely small amount o' glue was put on t' first 3" o' t' tab and t' two halves were pressed together. They were then pulled apart and t' glue allowed t' dry. Begad! Blimey! T' same thin' was done with t' aft end. Then a small bit o' additional glue was applied t' t' forward end o' t' tab and it was pressed together around a BT-60. Begad! Blimey! Alignment was carefully checked and t' resultin' cone was held together with me fingers for about 3 minutes. Avast! Blimey! When it be dry enough that thar be nay risk o' t' seam popping, me hearties, I glued t' aft end similarly, shiver me timbers, ya bilge rat, me bucko, checkin' for alignment along t' length o' t' shroud. T' middle section was nay yet glued.

After t' ends had dried, ya bilge rat, I slowly started tackin' down t' rest o' t' seam, workin' from front t' back and usin' a double glue joint. Begad! By doin' this, ya bilge rat, I was able t' keep t' edge o' t' shroud right on t' line, me bucko, and, as I realized thar would be a small bubble from nay havin' everythin' perfectly taut, shiver me timbers, that bubble would be hidden under t' air scoop t' be installed later.

As t' body shroud was drying, arrr, matey, I used a circle cutter t' remove t' inner circle from t' after bulkhead. Well, blow me down! T' after bulkhead color plate was then glued in place and allowed t' dry.

One o' t' things that made me normal scale clone Vulcan finally work right be t' incorporation o' an internal launch lug. Avast! I soon learned that for things t' go right out in t' field, me hearties, matey, t' lug needed t' run t' length o' t' BT. Ya scallywag! Doin' that was problematical when usin' just t' pieces o' lug I had on hand. Well, blow me down! Begad! This time, matey, I wanted t' use a single piece.

I finally found a 34" length o' 1/4" launch lug at Balsa Machinin' Co. Avast, me proud beauty! It was quite reasonably priced at $1.50 but then I learned t' shippin' policy. There was a $6 flat fee for shippin' plus a $3 surcharge for placin' t' order through t' mail. Avast! That would have brought t' price o' me launch lug up t' $10.50. Ahoy! Aye aye! Instead, I bought a package o' 6" lugs made by LOC from me local hobby shop and decided t' splice them.

I started with 2 lugs and ran a piece o' 1/4" through them t' keep them aligned. Begad! I then cut out a 3" wide strip o' typin' paper and smeared some white glue on one end. Avast! T' two pieces o' lug were butted together and set on t' end o' t' paper and t' glue was allowed t' dry. A toothpick be then used t' smear a thin layer o' glue on t' unrolled section o' paper and it was tightly wound about t' butt joint betwixt t' two lugs. Arrr! Keepin' t' paper tight be t' key t' keepin' t' 2 lugs aligned. Aye aye! When t' first splice be completed, I added another 6" lug for a total o' 3.

I printed up a second sheet o' t' page with t' fins, me bucko, tail, ya bilge rat, and air scoop. Well, blow me down! Blimey! I cut these elements out just as I did with t' first set but a few differences. Avast, me proud beauty! I did nay pre-fold t' second set. Blimey! I also cut off t' tabs intended for gluing. These were t' serve as t' "inner" surfaces.

I mated up each o' t' inner surfaces with its correspondin' outer surface and did a bit o' trimmin' where needed. Ya scallywag! I placed an outer surface face down on t' table and then test fit t' inner surface. Arrr! I wanted it t' come right up t' t' glue tab but still allow t' tab t' fold around it. Arrr! White glue was then applied t' half t' outer surface and smeared t' cover it. Aye aye! T' inner surface be set in place and pressed flat and then allowed t' get tacky. Aye aye! Ahoy! When t' joint was stable, I applied glue on t' other half and pressed t' rest o' t' inner surface into position.

At this point, me bucko, t' aft bulkhead consisted o' a piece o' 1/4" balsa with a hole in it and t' color plate glued t' its surface. Aye aye! I started t' shape it up by usin' an X-Acto saw t' trim off t' corners and remove bulk material. Begad! A belt sander was then used t' shape it t' t' outline o' t' color plate.

It seemed as if makin' a double layer for t' fins had really stiffened them up. They were more or less bent into t' right shape and t' mountin' process began.

I started with t' tail fin. Avast, me proud beauty! A layer o' white glue was applied t' one o' t' tabs. Avast! Begad! Blimey! It was then pressed into place and immediately removed and t' glue allowed t' dry. Avast, me proud beauty! When dry, me hearties, me hearties, a bit more glue was applied t' t' tab and t' fin was again pressed into place and held until t' glue set enough nay t' move. This was allowed a full hour before any more work be done.

When t' one side be completely dry, ya bilge rat, me bucko, t' process be repeated on t' other side. Ahoy! I waited betwixt sides because these double layer appendages are stiff and I did nay want t' displace anything.

I ordered a Cygnus 29mm t' BT-60 Motor Mount from Uncle Mike's Rocket shack t' use in this project. Begad! Ya scallywag! When it came in, construction o' t' motor mount was simplicity itself.

T' motor tube was marked 1/4" from one end. T' two centerin' rings were then test fit around t' tube. Aye aye! Well, blow me down! One fit just fine and t' other needed a good bit o' sandin' t' fit around t' motor tube. Aye aye! Begad! Once they fit, shiver me timbers, I placed one even with t' 1/4" mark and t' other flush at t' end. Ahoy! Begad! T' rings were then epoxied in place with 5 minute epoxy. Ya scallywag! A thrust rin' be provided and epoxied into t' end with t' flush centerin' ring. Begad! When t' epoxy on one side was set, I turned it over and painted in on t' other, buildin' up a good fillet on t' aft rin' an sealin' together t' thrust ring, ya bilge rat, motor tube and centerin' rin' on t' forward end. After that, it be just a matter o' waitin' for t' epoxy t' cure.

For me upscale Vulcan project, I needed BT-60 tubin' longer than t' 18" that comes standard from Estes. Well, blow me down! Blimey! Blimey! Blimey! I decided t' kill two birds with one stone and use a baffle for t' coupler. I chose t' FlisKits BAF60 Baffle since I had fair winds with their BAF55 in t' past.

T' first step in assembly o' t' baffle was t' thread t' Keelhaul®©™ thread through t' provided hole in t' after baffle plate. Avast, me proud beauty! I've had trouble doin' this before but this one fit just fine. Avast! Blimey! T' Keelhaul®©™ was knotted and then passed through a notch in t' outer edge o' t' baffle plate so that it would pass up through t' baffle. T' plate was secured in place with epoxy and epoxy was "painted" over t' face o' t' baffle plate and t' interior o' t' coupler t' act as an ablative surface. Ahoy! When t' epoxy had set, me bucko, t' Keelhaul®©™ thread was fed through t' notch in t' forward plate and that be installed with epoxy as well. Ya scallywag! I spent more time waitin' for t' epoxy t' set up than in actually puttin' this thin' together.

T' motor mount be installed in a full length BT-60 tube and t' motor tube protrudin' just a touch from t' end with 5 minute epoxy. Blimey! Begad! When t' epoxy be stiff, I set t' body tube down on its forward end and mixed another small quantity o' epoxy. Aye aye! This be poured into t' gap betwixt t' motor tube and t' BT.

One o' t' decisions I had t' make was about t' nosecone. I did nay have t' gumption t' try and research gettin' and exact upscale copy fitted for a BT-60. Instead, matey, I bought a package o' Estes BT-60 cones and picked one from t' two styles available. Begad! Ahoy! One was a Big Bertha type that is probably a better match but I chose t' ogive. I sanded down t' seam and then poured in some BBs t' serve as nose weight, ya bilge rat, followin' them with some epoxy t' hold them in place. I put just a touch under 4oz, me hearties, arrr, probably too much, ya bilge rat, but I wanted me 29mm motors t' have t' do a little work and I want t' get t' rocket back. Ahoy! I then painted t' NC gloss black.

I took t' tube with t' motor mount and marked it at 9" from t' aft end and cut it at this point. Well, blow me down! Blimey! I then took t' tube with t' baffle coupler and joined t' two together with yellow glue. Blimey! Blimey! This puts t' baffle fairly far back in case another has t' be installed at some point as a replacement. I figured that with t' nose weight I added, me hearties, it should be alright. I did nay cut t' forward tube at this point, me bucko, shiver me timbers, preferrin' t' wait until a later step.

I had been takin' me time installin' t' fins, tail, scoop, etc., wantin' t' make sure that each component is in t' exact right place. After joinin' t' body tubes, me bucko, I finally installed t' last fin.

T' built up launch lug I had put together earlier was glued t' t' BT with yellow glue. Arrr! T' paper wraps I had used t' join t' lugs acted like small standoffs were used t' do t' actual gluing. I set t' lug back just far enough t' protrude penetrate t' aft bulkhead.

T' body tube was inserted into t' after bulkhead, aligned and epoxied into place.

When t' epoxy joint betwixt t' bulkhead and t' BT was firm, shiver me timbers, t' assembly was slid into t' shroud as far forward as it could go. Blimey! Begad! T' impression o' t' launch lug could be seen on t' shroud and an X-Acto was used t' cut a notch t' pass it. Arrr! T' tube and bulkhead were then seated t' rest o' t' way forward and glued into place.

As t' bulkhead and BT assembly was dryin' into place in t' shroud, ya bilge rat, me hearties, me hearties, I glued t' cockpit into place with white glue. Well, blow me down! I decided t' go with t' more rounded version since it seemed t' fit t' contours o' t' rocket better.

I had t' shroud glued in place and t' BT extended quite a bit in front. Avast! Avast, me proud beauty! Now that everythin' was positioned as I wanted it, it be time t' cut t' excess BT from t' front o' t' rocket. Ya scallywag! Begad! I used t' shroud as a guide t' draw an X-Acto blade around t' tube multiple times. Avast, me proud beauty! Avast, me proud beauty! Each time went a little deeper until t' tube was cut.

One o' t' things that worries me about this rocket be t' stress on t' appendages under t' boost o' a mid-power motor. Aye aye! Avast, me hearties, me proud beauty! T' fins, me bucko, tail, and scoop were all put on with white glue. Ya scallywag! T' strengthen t' joints, me bucko, I mixed some epoxy and filleted t' joints. Arrr! I have no doubt this is stronger but it very much affected t' appearance o' t' shrouds wherever t' epoxy was in contact. Avast! T' remedy this, matey, I set t' Vulcan up in t' spray booth and began t' give it multiple coats o' Krylon Clear. Begad! This mimicked t' "wet" appearance o' t' epoxy and t' rocket a more uniform appearance.

Finishing:
Most o' t' finishin' for this rocket is "pre-done" in t' pre-printed shrouds. Aye aye! Begad! T' only thin' I added was t' sprayin' o' t' Krylon clear coat. Begad! This gave t' ink-jet printed shrouds a bit o' protection and tended t' hide t' epoxy.

Other than that, ya bilge rat, shiver me timbers, I sprayed a black plastic nosecone with glossy black paint.

Flight:
T' maiden flight o' t' Vulcan 60 be on a Roadrunner F60-4. Avast, shiver me timbers, me proud beauty! It took off and emulated t' behavior o' its smaller sibling, waggin' its tail all t' way. Begad! T' chute deployed on time and it drifted down nay too far away. Avast! I did learn that t' baffle was nay enough by itself t' protect t' chute in this rocket. There was a bit o' shreddin' and lots o' little holes. Avast, me proud beauty! Aye aye! Even so, I judged it worthy o' another flight.

Video o' t' first flight can be seen here.

For t' second flight, ya bilge rat, I wanted t' try a Roadrunner G80. Begad! Begad! I learned, ya bilge rat, however, ya bilge rat, ya bilge rat, that this particular motor would nay fit in t' motor mount. Aye aye! An Aerotech G would because o' t' smaller diameter at t' ejection end. I loaded an AT G77-7R. It took off and flew well but still corkscrewed. Blimey! It was noticed, shiver me timbers, ya bilge rat, however, me hearties, that t' corkscrewin' did nay begin until well into t' flight. Well, blow me down! Avast! Upon recovery, a small tear was noticed in t' shroud. Begad! Well, ya bilge rat, blow me down! It did nay seem t' be from landing.

Video o' t' second flight can be seen here.

Recovery:
A Keelhaul®©™ shock cord was installed in t' baffle and tied off t' a long piece o' sewin' elastic. Begad! A 32" Thermal Rider parachute was donated by Hartle Engineerin' for this project. It be assembled accordin' t' it's simple instructions and connected with a snap swivel.

T' first flight damaged t' parachute some with bits o' burnin' debris. Avast! I attribute this t' t' baffle bein' located just forward o' t' motor mount and gettin' t' full brunt o' its fury at ejection. This is contrary t' recommended practice but I did it thar t' give more room for t' chute. Arrr! I needed it. Still, matey, shiver me timbers, me hearties, t' chute be tough enough t' survive, brin' t' rocket down safely and even be used for a second flight. Ya scallywag! A regular plastic chute would nay have worked under t' same circumstances.

I did add 3 pieces o' waddin' for t' second flight and thar was no further damage.

Summary:
This really is nay a product so much as a project. Ya scallywag! I like t' Vulcan and already have a BT-70 version in mind with a 7 x 18 cluster mount.