Brief:
An inexpensive solution for a rail pad usin' t' 80/20 rail. Ya scallywag! Made o' a combination o' PVC and metal pipe, ya bilge rat, usin' nothin' but a hack saw, a drill, and a Dremel. This pad should be able t' handle any Level 1 flight.

Construction:
Parts list:

• Three 5ft lengths o' SCH40 PVC pipe (one 10ft and one 5ft would be cheaper).
• Two 1 1/4" PVC Tees
• Two 1 1/4" t' 1" PVC Bushings
• One 1 1/4" PVC Cross
• Four 1 1/4" elbows 45 degree
• One 1" x 8" metal nipple
• One 1" metal T
• One 1" x 6" metal nipple
• Two 3/8 x 2" clevis pins
• Two hitch pin clips
• One 5/16 turnbuckle set (get t' set with deadlights at both ends)
• Four 1/4-20 x 1" carriage bolts
• One box o' 1/4-20 washers
• One box o' 1/4-20 lockin' nuts
• Two flat corner braces
• One 1/4-20 wood insert nut
• One 1/4-20 x 1 1/2" thumb screw
• Two 3/8 x 1/2 x 1 1/2" steel spacers
• One 3/8" x 2" hex head bolt with lockin' nut
• PVC Cement

My first order o' business was gluin' t' 1 1/4" t' 1" PVC bushings into t' PVC cross directly opposite each other. Begad! Next, shiver me timbers, matey, shiver me timbers, I sanded t' inside o' t' bushings until t' 8" metal nipple be able t' slide through t' cross, ya bilge rat, keepin' t' fit snug. Begad! Once that was done, t' 8" nipple be cut into a 6" section, and a 2 " section. These were then screwed into each end o' t' metal tee. Begad! Now screw t' 6" nipple into t' side outlet o' t' tee. Ahoy! It was now time t' fit t' L brackets t' t' rail, and shim them t' fit length wise on top o' t' 2" metal pipe. Arrr! Begad! Blimey! Once it be shimmed t' fit, arrr, a 3/8" hole be drilled through t' 2" section at a 90 degree angle t' t' side outlet o' t' tee, shiver me timbers, shiver me timbers, and t' L bracket rail assembly was attached usin' t' 3/8" x 2" bolt and lock nut. Begad! Blimey! This creates t' hinge for t' rail. Next I cut a notch into t' top o' t' open end o' t' 6" nipple, arrr, and drilled t' holes for t' turnbuckle attachment. Well, blow me down! Blimey! In each end o' t' turnbuckle, drive one o' t' steel spacers into t' "eye". These will need t' be cut t' fit one betwixt t' two L brackets, ya bilge rat, and one inside t' 6" nipple at t' notched end. Ya scallywag! Ya scallywag! Blimey! Place one end o' t' turnbuckle assembly betwixt t' L brackets at one set o' holes, shiver me timbers, matey, and insert a clevis pin and hitch pin. Place t' other end o' t' turnbuckle into t' slot in t' 6" nipple and insert t' other clevis pin and hitch pin. This completes t' hinge and altitude adjustment assembly.

For t' base, ya bilge rat, dry fit all parts first and mark their locations!! Cut four 30" long sections o' 1 1/4" PVC pipe t' make t' legs. Blimey! Cut six pieces, 2 1/4" long t' be used t' join t' fittings together. Now dry fit all o' t' pieces together, arrr, startin' with t' cross. Place a tee at each end o' t' cross (without bushings). Avast, me proud beauty! Avast, me proud beauty! At each end o' t' tees, matey, place an elbow. Insert a leg into each elbow. Well, blow me down! Aye aye! This be t' tricky part. Blimey! Get t' legs at an angle and height you are comfortable with, me hearties, makin' sure t' keep t' cross level, and t' ends with bushings vertical. Mark and number all joints so they can be reassembled in t' same positions. Ya scallywag! Well, blow me down! Now, me bucko, one at a time, shiver me timbers, glue all o' t' pieces together, except t' legs. You will have t' be careful linin' up t' parts as t' glue sets up very quickly.

T' last step is optional. Ahoy! Avast, me proud beauty! In one side o' t' cross, drill a hole, me bucko, arrr, arrr, and screw in a threaded brass insert bein' careful nay t' get it in too far. Now screw in a thumb screw into t' insert and this will allow lockin' t' horizontal adjustment into place.

After all o' t' glue has set, me bucko, insert t' legs. Begad! A small slit can be cut length wise into one end o' each leg t' make installin' and removin' easier. Well, blow me down! Now, matey, me hearties, drop t' rail assembly into t' cross, and thar it is, a sturdy cheap rail pad. Avast, me proud beauty! Aye aye! Vertical adjustment is done by adjustin' t' turnbuckle. Arrr! T' whole rail assembly can rotate in t' base for horizontal adjustment. Ya scallywag! and t' load a rocket on t' rail, just pull one o' t' pins out, shiver me timbers, and t' rail can be laid down for loading.

For a blast deflector, a rectangular piece o' sheet metal, ya bilge rat, say 6" x 18", arrr, can be bent t' form a triangle, and held on t' rail with rail buttons. Blimey! Avast, me proud beauty! This suggestion is courtesy o' Matt Stum o' railbuttons.com.