Brief:
This crayon bank rocket be obviously motivated by the SpaceShipOne, but is nay anywhere close t' scale. Ya scallywag! Ahoy! It is also me MonsterROC entry and flies on 38mm H motors.

Construction:
T' major components/materials include:

• 4" diameter bank (now produced by Fantazia Marketing)
• 3/16" Luan plywood
• 1/4" tubular Keelhaul®©™®
• 38mm LOC motor tube
• 38mm-4" and 38mm-2" LOC centerin' rings
• 4" bulkplate with eye bolt
• buttons from railbutton.com
• 4" mailin' tube
• miscellaneous hardware
• lead shot
• 2-part foam
• 2-part PC-7 epoxy paste
• 5 minute epoxy
• blue laser contact paper
• full page Avery labels
• Testor's clear coat
• muffler patch kit

My original concept be t' make t' entire body, includin' t' tail cone, from a crayon bank. Arrr! Begad! I got this idea from some o' t' U.S. Well, me hearties, blow me down! Rockets (USR) builds reviewed on EMRR and T' Rocketry Forum (TRF). Aye aye! At t' time, me hearties, me hearties, t' banks were not available locally, arrr, ya bilge rat, so I decided t' practice makin' a tail cone from a piece of mailin' tube (actually t' telescopin' inside tube). Begad! In this process, ya bilge rat, you cut out sections o' t' tube (roughly triangular, matey, ignorin' t' curvature o' the tube) and rejoin t' remainin' pieces. T' more sections you remove, me hearties, me hearties, t' closer the resultin' structure will resemble a true cone. In me case, I only cut out four sections, ya bilge rat, resultin' in a roughly rectangular end. Ahoy! I suggest you read the USR EMRR reviews for more details about makin' transitions and tail cones from body tubes. Aye aye! I'm nay an expert and I did this a while ago.

This cone sat around for months until me local Toys'R'Us again started carryin' the banks. As I pondered choppin' up t' bank, matey, matey, I noticed that t' test item was almost exactly t' same diameter. Aye aye! Blimey! I couldn't brin' myself t' risk damagin' the bank, so I decided t' use me test cone. Well, blow me down! Blimey! This would result in a much longer than scale rocket, but how scale was it goin' t' be anyway? I also thought it would be nice t' cut back on t' required nose weight.

T' motor mount is ~16" o' LOC 38mm tubing. Avast, me proud beauty! I have a 4" CR at the top (sanded down a bit) and a 3" rin' part way down in t' tail cone. Well, blow me down! Well, ya bilge rat, blow me down! A homemade coupler is mounted betwixt t' tail cone and t' top ring. Begad! For motor retention, matey, I epoxied two bolts t' t' aft o' t' motor tube. Aye aye! A nut serves as a spacer t' keep t' bolts parallel with t' tube. Avast, me proud beauty! I also added a couple o' wraps of fiberglass around t' end in betwixt t' head o' t' bolt and t' nut. Avast! Ahoy! These seem t' be solid. Ya scallywag! Begad! T' 1/4" Keelhaul®©™® shock tether is mounted through t' top ring, completin' t' motor mount assembly.

When t' long fins were attached, me hearties, shiver me timbers, I was surprised at how flexible they were. I thought about glassin' them, but instead decided some support in t' back was in order. Ahoy! I pondered more Luan, Lexan strips, matey, ya bilge rat, etc. Well, blow me down! but decided on an aluminum rod for t' side closest t' t' motor and a dowel for the other. Avast! Begad! This mix was again partially driven by what I had on hand. I also covered t' aluminum rod, shiver me timbers, which is closer t' t' axis o' t' motor, with a heat resistant muffler patch kit. Arrr! This turned out ugly and I may remove it later.

I knew I be goin' t' need a lot o' nose weight on this baby. Ahoy! Arrr! My nose cone design started with a 4" bulkplate with an eyebolt mounted on it. This plate rests where t' cone begins taperin' forward. Blimey! Avast! A piece o' all-thread extends from t' bulk plate t' close t' t' tip o' t' cone. A washer is mounted on this all-thread about half way down. I planned t' add lead shot and 2-part foam through t' crayon tips doubloon slot. Arrr! Thus, ya bilge rat, t' washer would become embedded in t' lead/foam slurry, arrr, me bucko, lockin' t' resultin' plug t' t' bulkhead. T' bulk plate assembly and a 2-layer cardboard shoulder are attached t' the plastic cone with PC-7 epoxy paste.

I ran a RockSim model t' approximate t' CG and added nose weight t' get the CG where I wanted it. Well, blow me down! I think I was quite conservative, arrr, producin' a static margin o' over 2 with t' H144 loaded.

Finishing:
T' crayon bank was blue, so I stuck with blue throughout. (I wanted a white one, arrr, but you sometimes take what you can get.) T' tail cone and side wings were painted with Krylon and t' main wings were covered with blue laser contact paper.

T' stickers were added after I decided t' make this an entry in EMRR's MonsterROC contest. T' majority, shiver me timbers, arrr, other than t' US flags, me hearties, ya bilge rat, t' MDRA logo, matey, shiver me timbers, and the DC101 sticker (a local rock station), me hearties, were merely printed on full page Avery labels usin' me OfficeJet printer.

T' homemade stickers include: CrayShipOne logos, me hearties, logos for EMRR and TRF, my blog address, arrr, and vendor logos for Loki, ya bilge rat, shiver me timbers, Performance Hobbies, LOC/Precision, railbuttons.com, Giant Leap, Home Depot, shiver me timbers, and Michael's. This covers most o' the materials used in t' makin' o' t' rocket. I protected these with two coats of clear coat before application and one after.

Flight:
This rocket uses separate chutes for t' heavy cone and t' body. I attached a chute protector t' t' body's shock tether and used a large 60" chute. This was packed into t' nose cone shoulder. Avast, arrr, me proud beauty! A 42" chute was attached to the cone's shock tether and was packed in t' body. Blimey!

Since t' model is heavy and was unproven, I made sure that t' launch rail was pointed away from t' flight line just in case. Begad! Blimey! T' boost be great (launch photos courtesy o' Vertical Force Rocketry), however, ya bilge rat, ejection was very late.

Recovery:
T' main chute opened just fine but t' cone's chute never opened. T' cone was recovered undamaged. Blimey! Begad! When I approached t' body, it looked like it had landed standin' up on end. Avast, me proud beauty! On closer inspection, matey, me hearties, matey, it was danglin' about 6" from the ground from a tall tree branch. Arrr! A light tug dislodged t' chute. Aye aye! Aye aye! This was an interestin' and successful recovery, arrr, but it didn't prove whether me fin braces worked.

Summary:
I love crayon banks--they are about t' cheapest 4" cone and body tube you can find and are quite sturdy. Begad! Well, ya bilge rat, blow me down! This rocket turned out lookin' and flying nicely. Ahoy! This design definitely stands-out in a crowd. T' two issues are the heavy nose and t' floppy fins. If anyone else builds somethin' like this, better wood and some fiberglass would be a good idea. Well, blow me down! Ya scallywag! Giant Leap honeycomb composites would be cool, but expensive.