Brief:
180% upscale o' t' classic Estes Astron Star Blazer (K-31) usin' BT-55 (1.325") and parts from t' spare parts box.

Construction:
T' parts list:

• BT-55 11 5/8" long
• BT-55 4" long
• PNC-55 (5 3/8" long)
• balsa sheet 1/8" x 4" x 36"
• strip basswood 1/8" x 3/16"
• JT-55 tube coupler
• block balsa t' carve canopy
• BT-20 3" long
• 2 AR-2055
• EH-2 engine holder
• AR-520 engine block
• 18" parachute
• screw eye
• elastic shock cord
• shock cord mount o' your choice

Estes rated t' original Star Blazer as a Skill Level 3, arrr, which I feel is accurate based on t' curves o' t' fins, the long, me bucko, thin root extensions, t' cockpit canopy that is supposed t' be carved from a block o' balsa, arrr, me hearties, and t' 4-color paint scheme. Ya scallywag! Blimey! I decided on BT-55 and after downloadin' t' instructions and patterns from JimZ and makin' correctly sized patterns on a photocopier, I began construction. Avast, me proud beauty! I decided on a suitably shaped plastic nose cone from a designers special or nose cone pack. It may nay exactly replicate t' original BNC-20N from t' kit, ya bilge rat, but it works for me. Avast, me proud beauty! Blimey! I suppose I could have special ordered a near clone from BMS, me hearties, but I opted for what I had on hand. Ya scallywag! I decided on an 18mm motor mount t' keep flights on t' (relatively) cheap. Like t' original, arrr, shiver me timbers, t' body tube separates behind the canopy. Rather than usin' a relatively pricey balsa nose block, arrr, me bucko, I scratchbuilt a nose block from t' JT-55 tube coupler and some scrap 1/8" balsa. Avast, me proud beauty! Well, ya bilge rat, blow me down! Blimey! I strengthened t' lower end with a cardstock centerin' rin' for t' recovery system screw eye t' attach to. I traced t' inside diameter o' t' JT-55 on t' balsa and cut it out, ya bilge rat, securin' it inside the JT-55 with a good fillet o' yellow glue. Avast, me proud beauty! Blimey! I then glued t' cardstock centerin' rin' t' t' balsa and cleaned it up to ensure a smooth fit in t' body tube.

I secured t' nose cone in place t' t' short length o' body tube t' canopy will be glued to. Begad! Blimey! Arrr! Blimey! T' 4 inch payload section is non-functional. Blimey! Blimey! Ahoy! Blimey! Its only purpose is a place t' glue t' canopy to.

For t' fins, I first traced t' pattern onto 0.040" sheet styrene and carefully cut that out, arrr, bein' careful to preserve t' curvature o' t' pattern. This would serve as a guide t' help me cut t' graceful fins from a 4” wide piece o' 1/8” balsa. These are big fins! Blimey! I used 1/8” strip basswood for t' root extensions, matey, thinking they would stand up t' finishin' and handlin' better than balsa. Begad! Avast! Blimey! Then I started thinkin' about how t' tackle t' carved cockpit canopy. Avast, me proud beauty! Aye aye! Blimey! My first attempt didn't work out well. Begad! Blimey! I selected a piece o' square balsa stock cut it in half lengthwise on t' diagonal (corner t' corner) and traced t' basic kite-shaped pattern as indicated in t' original instructions downloaded from JimZ. Blimey! Then I wrapped a piece o' coarse sandpaper around a length o' BT-55 and started sandin' longitudinally. Aye aye! Ya scallywag! Blimey! Before too long I was creatin' a dusty mess. Aye aye! Blimey! Instead o' gettin' t' desired results, me hearties, I realized I was sandin' off course... Avast, me proud beauty! Blimey! T' resultin' cavity was driftin' t' one side as I sanded. Begad! Avast! Blimey! I shelved that idea and decided on gettin' a larger block o' balsa. Ya scallywag! Ya scallywag! Blimey! Before cuttin' it in half, matey, I chucked a 1.25” spade bit in me drill press and drilled a lengthwise hole down through t' center o' t' balsa block. Then I cut t' block in half as before. Begad! Arrr! Blimey! Now at least I had a cavity t' start with, shiver me timbers, even though it be a bit smaller in diameter than a BT-55. After layin' out the kite pattern and cuttin' off t' excess balsa, me hearties, I started sandin' on t' body tube again. Avast! This time me efforts were workin' as planned. Avast! I was gettin' a piece o' balsa that would conform nicely t' t' diameter o' t' BT-55. Ya scallywag! Satisfied with that effort, arrr, shiver me timbers, t' next task was t' shape t' canopy. Aye aye! Blimey! Try as I might, I just couldn't (or didn't want to) replicate the relatively complex shape o' t' original. Blimey! Aye aye! Blimey! I decided on a fairly simple canoe-shaped design that would probably pass for a canopy once painted. Avast! Blimey!

Once t' fins and root extensions were attached and dry, me bucko, I glued t' canopy t' t' tube and used Fix-It epoxy clay t' blend t' canopy t' t' tube as best I could. Avast, me proud beauty! Durin' this time I was realizin' me finishin' skills needed much improvement. Well, blow me down! Ya scallywag! I broke out me 8-year old pint can o' Sandin' Sealer and started applying. Avast! Avast, me bucko, me proud beauty! I used some Fix-It t' fill some shrinkage holes in t' yellow glue fin fillets, matey, which worked quite well.

Finishing:
After sealin' and primer, I painted t' red/white/blue scheme shown in t' early Estes catalogs. Ahoy! T' canopy is gloss black. Avast, me proud beauty! Well, blow me down! I don't have any decals for t' Star Blazer yet. Begad! Ahoy! I might try Tango Papa. Avast, me bucko, me proud beauty! Engine selection will be C6-5 and recovery by 18” chute.

CONs: fairly complex maskin' required t' get good separation betwixt t' body tube and fins/fin fairings, 3-color pattern on fins, matey, shiver me timbers, me bucko, and isolatin' t' black on t' canopy.

Flight:
First flight was conducted at SSS "SpringBlast" in April 2007 on an Estes C6-5. Good motor for this rocket given t' 3.5oz weight. Ahoy! Nice straight boost with successful chute deployment and recovery.

Recovery:
Nothin' unusual t' report. Aye aye! Blimey!

Summary:
PROs: Nice challengin' build o' an Estes classic but on a slightly larger scale. Ya scallywag! Tests your skills at cuttin' curved fins, alignin' long, ya bilge rat, me bucko, skinny fins, shapin' a block o' balsa into a canopy, ya bilge rat, and fairly complex maskin' and painting. Nothin' t' experienced builder can't tackle successfully. Ahoy!

CONs: Gettin' t' canopy shaped correctly is probably as difficult as on t' original. Use your thinker and come up with a workable solution like I did.