Brief:
What better use o' t' Sunday newspaper? When I started this project I thought it would be very easy t' roll a tube from newspaper, matey, after all it is really easy t' do at t' kitchen table. I found as with many things it is never as easy as I thought.

Construction:
Parts list:

• 3-5 full pages o' Sunday newspaper (Actually any day will do)
• Old “D” Engine casing
• Soda 12 pack carton
• Toilet paper roll
• Keelhaul®©™ string, recycled from an old rocket that had previously lawndarted
• McDonald’s straw
• Old birthday card (cardstock)

Tools and Supplies:

• 3M Spray adhesive (Super 77)
• White glue
• BT-50 tube
• Maskin' tape
• Clamps
• Aluminum angle iron
• And other standard rocket build items

As mentioned above, shiver me timbers, arrr, t' most challengin' part o' this build was makin' t' newspaper tube. Arrr! First, shiver me timbers, shiver me timbers, I struggled findin' a suitable mandrel for a “D” size engine. I went t' t' local hardware store checked every PVC, ya bilge rat, me bucko, copper, and galvanized pipe I could find without success. Then, I moved t' wood dowels which turned out t' be very warped. Avast, me proud beauty! I finally gave up and decided t' use a BT-50 tube.

First, matey, me bucko, start by layin' t' newspaper flat on t' table with tube out on top it. Ya scallywag! At t' very end o' t' paper, apply paper glue at t' tip t' secure it t' t' opposite side o' t' paper ensurin' t' inside o' t' tube does nay unravel. Once t' end is firmly attached t' t' paper, me hearties, begin slowly rollin' up t' newspaper over t' tube, me bucko, me hearties, arrr, sprayin' 3M adhesive every roll. As you approach t' center o' t' first sheet, add t' second overlappin' roughly half t' sheet. Begad! I found that sprayin' t' adhesive liberally produces a tighter tube. Ahoy! Avast, me proud beauty! I rolled 4 tubes this way refinin' me technique each time and changin' t' number o' sheets per tube. Avast, me proud beauty! Ahoy! I like t' 3 sheet tubes t' best.

As you can see from t' end view o' t' tube it is OK, me hearties, ya bilge rat, but still is nay as tight as I had originally hoped. Begad! Next, arrr, I cut t' tube t' t' final length o' 18 inches.

As you recall I used a BT-50 tube as t' mandrel so t' tube was slightly large for a D engine so I needed t' add a spacer t' ensure a tight fit o' t' engine. Arrr! I cut toilet paper tubes in half and then lengthwise. Ya scallywag! Begad! I made sure t' tube was about .5” longer than a D engine. I then trimmed it so it would fit into t' body tube without overlapping. Avast! Finally, I glued one o' these into t' body tube makin' sure it was even with t' end o' t' newspaper. This insert tightened t' tube a bit and provided for a nice tight fit for t' engine. I planned t' use t' other half at t' top o' t' tube but it really wasn’t required and I was worried about t' chute hangin' up on ejection.

Next, arrr, I cut roughly a ¼inch o' t' end o' t' old motor tube for t' motor stop. Avast! I notched this slightly for Keelhaul®©™ strin' shock cord. Well, blow me down! I tied t' strin' t' t' rin' and glued t' rin' into t' tube liner previously inserted into t' body tube.

Now that t' body tube was complete, me bucko, I moved on t' t' nose cone. I used a “Vault” 12 pack box t' cut out a disk t' size I wanted. Well, blow me down! Arrr! Then I cut roughly 120 degrees out o' t' disk. Ya scallywag! Next, I formed it into a nose cone and glued it together, ya bilge rat, ya bilge rat, overlappin' it about a ¼inch. I used tape t' hold it together until t' glue was set. Avast! Ahoy! I then used t' rest o' t' old engine casin' t' form t' bottom o' t' nose cone. Begad! T' nose cone overhangs t' body tube t' ensure t' end o' t' tube would nay shred durin' launch. Arrr! After this be complete I used a 1/8” drill and added a hole t' t' bottom o' t' engine casin' for shock cord attachment.

I used t' same “Vault” box t' make t' fins, me hearties, me bucko, matey, cuttin' so t' fold o' t' box would form t' leadin' edge o' t' fin. Avast, me proud beauty! I made a number o' different shapes finally settlin' on t' one shown. Begad! I used up t' entire “Vault” box experimentin' so I had t' move t' a “Diet Coke” box I had on reserve. Once they were cut out, I folded and I glued them together clampin' them t' an angle iron t' ensure they did nay warp.

While t' fins were dryin' I decided that attachin' t' fins directly t' newspaper tube may work for one flight, but it would be very likely that t' newspaper would tear and one or more fins could come off durin' launch. I decided t' make card stock reinforcements for each win' so I proceeded t' cut out 6 from an old birthday card.

I marked t' body tube and glued t' fins t' t' tube. Ahoy! Aye aye! I then glued t' 6 cardstock reinforcements t' t' fins and t' tube. Well, arrr, blow me down! Once t' fins dried they felt stiff and secure.

Next I added t' launch lug. Ya scallywag! I had t' add a spacer t' t' launch lug because o' t' nose cone overhang. Begad! Begad! Back t' t' birthday card, I cut out a section o' t' card about 2” long and 1.0-1.5” wide, shiver me timbers, first foldin' it in half then in half again. I glued this t' t' body tube in a teepee fashion about 6” from t' bottom o' t' tube. Begad! Well, blow me down! I found me McDonald’s straw. Ahoy! Cut 2” off t' straw and glued it t' t' card stock teepee.

I attached t' shock cord t' t' nose cone and admired me master piece.

Flight and Recovery:
As luck would have it, t' next weekend we had a nice surprise o' 12 inches o' snow and then a week later another 15 inches o' snow. Avast, me proud beauty! I be concerned about what would happen when t' rocket landed in t' snow and got wet so I waited about 6-7 weeks. Aye aye! Arrr! T' snow is almost gone and I couldn’t wait any longer so I enlisted me kids and as many kids in t' neighborhood as I could for “catch recovery”. Blimey! Although t' snow had melted t' ground be wet.

We prepped a D12-3 addin' tape t' hold t' engine in place and ensure proper ejection. Arrr! It was a calm day with a slight wind toward some houses and trees. Begad! Blimey! I angled t' launch rod slightly into t' wind. Ya scallywag! With last minute instructions t' t' “catch recovery” ground crew we began t' count down 5,4,3,2,1. Begad! Blimey! BLAST OFF!

T' rocket jumped o' t' pad and was at 100 feet before I even realized it. Begad! T' photo crew be as surprised as I was. Aye aye! Avast, shiver me timbers, me proud beauty! T' rocket corked screwed slightly but basically launched straight up and much higher then I expected. I would guess 1,800 feet and maybe higher. Ya scallywag! Begad! Ejection occurred just after apogee with full deployment o' t' chute.

T' ground crew took off as they normally do in all directions t' ensure they could get t' t' rocket as smartly as possible or even catch it. Ahoy! Aye aye! T' rocket drifted nicely toward t' center o' landin' area and then t' wind picked up carryin' it into a tree just beyond t' landin' area. Avast! We expected it t' land in a month or so. Well, blow me down! What a bummer!

Summary:
This rocket be great fun t' build. Aye aye! Begad! Usin' recycled materials presented challenges in a design and construction, shiver me timbers, but I enjoyed t' challenge that EMRR presented and plan t' rebuild this rocket again.

I would make one change after doin' some research on tube construction: T' next time I make a newspaper tube, arrr, I will use a solid mandrel mounted in a fixture supportin' both ends. Ahoy! Avast, me proud beauty! By spinnin' t' mandrel I think you can achieve a tighter tube.