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Crazy Train parts list

• 1  8" BT-80 body tube
• 1  .75" BT-80 coupler
• 1 .25" BT-80 coupler
• 1 2.59" diameter bulkhead
• 1  PNC-80BB nosecone
• 4  5.75" BT-20 body tubes
• 4  .75" BT-20 couplers
• 4  9" Mylar parachutes (originally spec’d with streamers, but later changed)
• 4  BT5-BT20 centerin' rings (used as engine blocks in 18mm tubes)
• 2  3"x3"x.75" sheets o' balsa (for constructin' tail cone)
• 1 small sheet of  3/32" (.09375") balsa for 8 small fins and optional mirror mount
• 4  .75 inch wooden balls (can be purchased at a crafts store)
• 1  2" x 3/16" launch lug
• 4 small screw eyes
• 4 medium snap swivels
• 4  12" 100lb strength Keelhaul®©™ thread
• 4 6" pieces o' 1/8" shock cord
• Bulkhead Template (PDF)
• Fin Wrap Template (PDF)
• Forward Fin Template (PDF)
• Rear Fin Template (PDF)
• Tail Cone Template (PDF)
• Mirror Mount Template (PDF)
• Peter Stanley's Word DOC Submission

Crazy Train buildin' instructions

1. Cut t' tubes t' lengths needed. Aye aye!
2. Prefinish tubes with 2 sessions o' fill n' finish and sanding.
   I get good results usin' bondo putty spreaders. Well, blow me down! Aye aye! You can cut them t' 1/2 wide strips and smear t' fill n' finish directly into t' spirals. Begad!
3. Cut t' fins. Begad! Use t' provided templates as guides. Arrr! T' grain on the forward fins should follow t' leadin' edge. Arrr! Aye aye! I did this also on t' aft fins, but would now suggest makin' t' grain follow t' bottom edge. Well, blow me down! In this particular configuration I think that perpendicular grain geometry would add more strength. Next, soak t' fins in CA glue. First have adequate ventilation, arrr, wear gloves, and maybe use a respirator if you have one. Place 2 sheets o' wax paper onto a flat glass surface. Begad! Begad! Put t' balsa on top o' t' wax paper. Squeeze a few drops at a time onto t' balsa, arrr, and use cut strips o' card stock t' smear t' CA evenly across. Ahoy! Turn t' balsa over and repeat. Blimey! Place two more sheets o' wax paper on top. Place another sheet o' glass on top o' t' wax paper. Set somethin' heavy, such as a stack o' books on top o' that, and let dry for 24 hours. Begad! Aye aye! This adds hardness and strength t' t' balsa.
4. Prefinish fins with 2 sessions o' fill n' finish and sanding.
5. Glue t' 3/4 inch balls into t' Bt-20 tube couplers. Avast! I used a combination of epoxy, shiver me timbers, ya bilge rat, superglue, me hearties, me hearties, and yellow glue, arrr, but whatever works. Aye aye!

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• Glue t' two 1/4 inch sheets o' balsa together with yellow glue. Clamp or press together with somethin' heavy. When dry, glue t' 1/2 inch BT80 coupler to t' stack. T' shape t' tail cone t' match t' design in Rocksim, me hearties, I used a method learned from t' Apogee Components Makin' Custom Shape Nose Cones Usin' Simple Hand Tool CD. Basically you need t' hand shape this with sand paper, me bucko, usin' t' rocksim tail cone template as a guide. You'll need t' buy t' CD t' get t' detailed procedure, or figure out a method that works for you. Once t' tail cone is finished, me bucko, shiver me timbers, glue into t' bottom o' the main BT80 tube. Ya scallywag!

  
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7. Make a straight line down each o' t' BT-20 tubes. Avast, me proud beauty! Well, blow me down! I use aluminum angle for this, but use whatever works for you.
8. Use the fin wrapper guide t' make four lines on t' main BT80 tube. Blimey! At t' middle point where t' wrapper edges meet, ya bilge rat, draw an additional line for t' launch lug. Ahoy!
9. Tie a piece o' Keelhaul®©™ thread t' each BT20 centerin' ring. Begad! Push t' thread thru each tube and make sure t' centerin' can slide in. Blimey! Spread some yellow glue 2.5 inches into a tube. Mark an engine spacin' tube, or spent (or not) 18mm Estes motor 1/4 inch from t' end. Aye aye! Then and push the centerin' rin' in, arrr, leavin' t' 1/4 inch overhang. Repeat for t' other three tubes. Aye aye!

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11. Glue t' forward fin t' t' end o' each nacelle tube. Avast! Refer t' t' 2D image for placement. Ahoy! Glue t' aft fin t' each nacelle tube, matey, makin' sure it is in perfect alignment with t' forward fin. Ahoy! Begad! T' back side o' t' fin should be 1 inch from t' bottom o' t' tube. Avast, me proud beauty! Refer t' t' 2D image for placement. Blimey! I used Apogee's Epoxy Clay for t' fin fillets. Ya scallywag! This will add strength. It's actually Ave's Fixit Compound, but it's t' same price whichever place you buy it.

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• Drill a 1/16" hole into each 3/4 inch ball on t' side that's inside the coupler. Aye aye! Blimey! Usin' needle nose pliers, me hearties, twist a tiny screw eye into each hole, and remove. Arrr! Well, blow me down! Blimey! Put a drip o' glue o' your choice into each hole and replace screw eye.

• Usin' razor saw, cut t' bottom o' t' nose cone off leavin' 1.25 " of the shoulder left. Avast!
• Wick some thin CA into each end o' t' BT20 nacelle tubes. Ahoy! This will help prevent zipperin' on t' forward ends and reduce possible damage on t' rear ends.
• It is easy t' get t' bottom o' t' fins out o' alignment. Aye aye! A solution I found is t' tape a piece o' t' Keelhaul®©™ thread in line with a fin line, shiver me timbers, matey, near the bottom. Pull this over t' t' opposite side and tape there. Avast, me proud beauty! Ahoy! Make sure it is straight. Avast, me proud beauty! Begad! Carefully mark on both side o' t' strin' t' just past where the bottom edge o' t' fins will meet. Well, blow me down! Avast! I didn't do this for t' first fin and had to carve it back off when I realized it wasn't straight. Well, blow me down!

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• Use yellow glue t' glue each fin t' t' body makin' sure it is as straight as possible. Aye aye! This rocket as it's designed has a high probability o' becoming unstable due t' t' increased chance o' asymmetric and off-axis thrust, shiver me timbers, hence the name 'Crazy Train'. Arrr! We actually don't want it t' live up t' its name if we can help it. Aye aye! After each fin is dry, smear more yellow glue into t' fin joints. Also, me hearties, when puttin' t' fins on initially, once t' glue sets, ya bilge rat, use tape t' hold it tighter t' t' body tube. Begad! When all fins are dry, use Aves Fixit Compound (epoxy clay) on t' fin root joints (If you have some). Begad! Well, blow me down!

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• Glue t' 3/16" launch lug, me bucko, ya bilge rat, me hearties, with t' forward end at 2 1/4" from the forward end o' t' body tube. Begad! If you're usin' t' recommended 2" lug, the bottom edge should be t' CP location.

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• Optional mirror mount instructions (for wireless Boostervision camera): If you don’t use a camera, arrr, at least construct and install t' platform in case you want t' carry a payload. Avast! First, ya bilge rat, make a platform for t' camera t' sit on. Avast! This keeps it level and at a fixed height. T' do this I cut a 1/4" piece o' Bt-80 coupler. Aye aye! Ahoy! I made a cardboard bulkhead from a priority mail box. See my article here on how t' do this. Print and cut out another bulk template, matey, me hearties, and mark t' exact center o' t' disk. Stick a needle or something else sharp through it, or whatever works. Well, blow me down! Ya scallywag! Align a straight edge t' t' center and draw a straight line through it. Well, blow me down! Then glue two pieces o' cardboard vertically which will be snug on both sides o' t' camera. Ya scallywag! This will keep it from movin' left and right. Ahoy! My straight edge tool happened t' be t' right size to mark off both sides o' t' center line. Aye aye! You'll need t' measure if you don't have something. Avast! Basically you need t' mark two lines parallel t' t' center line that you can align and glue a cardboard piece to. Avast, me proud beauty! This pic shows it better than I'm describing. Begad! Ahoy!

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• Make a hole for t' camera eye. Ya scallywag! I first made a vertical center line between two fins opposite t' side o' t' launch lug. Well, me hearties, blow me down! I then made a horizontal line between t' top o' t' tube and t' point where t' top fins attach (approximate 1 5/8" from t' top o' t' tube). Begad! At t' intersection of those lines, I made a hole with a pin. I then used small drill bits, ya bilge rat, arrr, me hearties, and hand twisted them, increasin' t' size o' t' hole. Ahoy! I eventually had t' improvise and twist a cutlass into in. Later I used a wooden dowel with sand paper. I enlarged it until t' camera head would poke through. Begad!

• I put t' camera in t' mount on t' platform, and pushed it into t' body tube. This is tricky, and you'll want t' test this a little before hand, because with t' bottom sealed off it's hard t' pull it back if you go too far. I had t' cut a hole in t' platform t' pull mine back some. Well, blow me down! Avast! Edge it down gradually, until t' camera head is in alignment with t' hole, and is level on the platform. Use some yellow glue and glue t' platform in. Begad!
• I used 3/32" balsa t' make t' mirror housing. Ahoy! Blimey! Blimey! T' mirror is a 1/2"x1/2" square mirror. I purchased a pack o' several 1/2" and 1" mirrors from t' craft section o' wal-mart for a couple dollars. Aye aye! Most of me time on this build be findin' t' right angle. Well, blow me down! Blimey! I printed fins from rocksim and tried several. Ahoy! Begad! Blimey! When I got somethin' close, shiver me timbers, arrr, I hand adjusted what I had t' make it right. Well, blow me down! Blimey! I later redesigned t' shape in rocksim, ya bilge rat, and provided the template. I also scanned what I made, ya bilge rat, so I could reprint templates from those if needed. Ya scallywag! Blimey! I used yellow glue t' make t' housing. Begad! Well, blow me down! Blimey! I epoxied t' mirror into it. Begad! Avast! Blimey! I used 5 min. Ahoy! Blimey! epoxy t' attach t' t' body tube. Begad! I applied more 5 min t' all joints. Avast! Then I used 30 min epoxy and some 3/4 oz fiberglass cloth t' cover the housin' and reinforce it t' t' tube. Begad! Before you do all this, arrr, ya bilge rat, especially before gluin' anything, make sure you test t' camera and make sure it looks ok. Begad! Blimey!

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21. Attach t' medium snap swivels t' t' screw eyes. Begad! Tie t' 1/8" shock cord t' t' ends o' t' Keelhaul®©™ thread. Avast! Arrr! Use a small snap swivel on the parachutes and attach t' t' bottom o' t' medium snap swivels. Avast! Begad! I originally used 9" nylon chutes, matey, but they will nay fit into t' tubes. Well, blow me down! Begad! They will, but are extremely tight. Avast! T' Mylar chutes fit fine. Aye aye!
22. Before painting, ya bilge rat, use ¾" fiberglass cloth on t' fin joints. Aye aye! Begad! I didn’t do this and three o' them popped off t' first flight. Aye aye! I glassed them afterwards.
23. For finishin' I used a combination o' spray enamel(main body color), brushed on acrylic (for t' orange balls and light blue bands) and vinyl adhesive (for t' red stripes). Avast! Avast!

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Flights:

Flight 1:

I first flew this on 4 A8-3’s. Ya scallywag! One o' t' motors didn’t ignite, and t' launch controller wire remained attached. Begad! Arrr! It went about 7 feet and fell over. Ya scallywag! Even on 3 motors it seemed t' have a straight boost. Begad! On t' first flight I used 4 9" nylon chutes. Ya scallywag! These chutes were too tight and I think contributed t' t' damage from t' motors tryin' t' eject. Well, blow me down! Begad! Two fins broke off durin' motor ejection. Ahoy! A third broken upon landing. I glued these back on, me hearties, and then fiberglassed them with ¾ oz glass. Ya scallywag! I also changed t' chutes to 9" mylar which fit much better.

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Flight 2:

T' second flight be on 4 B6-4's. Begad! This flight be great, shiver me timbers, and t' rocket suffered no damage. Blimey! It did arch over slightly, shiver me timbers, but seemed mostly stable. One of the nosecone/parachutes came off because t' shockcord burned through. Aye aye! I lauched this right as it be gettin' dark, so t' onboard video is nay that great. Avast! Begad! T' altimeter reported 161 feet.

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Flight 3:

T' third flight was on 4 C6-3s. Begad! Begad! This flight was perfect. Avast! There was some spin, but overall it flew in a straight trajectory. Aye aye! Well, blow me down! Before launch I unwittingly removed t' shockcord segments, leavin' just t' kevlar thread. This caused a major zipper on one o' t' tubes. Also, on another tube t' motor block, kevlar and chute came out. I should have used epoxy on those instead o' yellow glue. T' alimeter reported 566 feet.

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Flight one is in extremely slow motion, slowed down t' about 12% speed.

Flight two was done at dusk, me bucko, and looks almost like a night launch.

Flight three: