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, me hearties, which I feel is accurate based on t' curves o' t' fins, the long, thin root extensions, t' cockpit canopy that is supposed t' be carved from a block o' balsa, and t' 4-color paint scheme. Begad! 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. Arrr! 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, but it works for me. Begad! I suppose I could have special ordered a near clone from BMS, me bucko, but I opted for what I had on hand. Arrr! Avast! I decided on an 18mm motor mount t' keep flights on t' (relatively) cheap. Ya scallywag! Like t' original, ya bilge rat, t' body tube separates behind the canopy. Avast, me proud beauty! Begad! Rather than usin' a relatively pricey balsa nose block, matey, I scratchbuilt a nose block from t' JT-55 tube coupler and some scrap 1/8" balsa. I strengthened t' lower end with a cardstock centerin' rin' for t' recovery system screw eye t' attach to. Avast, me proud beauty! Blimey! I traced t' inside diameter o' t' JT-55 on t' balsa and cut it out, securin' it inside the JT-55 with a good fillet o' yellow glue. Begad! 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! Avast, me proud beauty! Blimey! T' 4 inch payload section is non-functional. Blimey! Avast, ya bilge rat, me proud beauty! 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, matey, bein' careful to preserve t' curvature o' t' pattern. Begad! Blimey! 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, thinking they would stand up t' finishin' and handlin' better than balsa. Avast! Blimey! Then I started thinkin' about how t' tackle t' carved cockpit canopy. Ahoy! Blimey! My first attempt didn't work out well. Aye aye! 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. Then I wrapped a piece o' coarse sandpaper around a length o' BT-55 and started sandin' longitudinally. Before too long I be creatin' a dusty mess. Avast, me proud beauty! Blimey! Instead o' gettin' t' desired results, ya bilge rat, me bucko, I realized I be sandin' off course... Avast, me proud beauty! Blimey! T' resultin' cavity be driftin' t' one side as I sanded. I shelved that idea and decided on gettin' a larger block o' balsa. Begad! Blimey! Aye aye! Blimey! Before cuttin' it in half, me hearties, I chucked a 1.25” spade bit in me drill press and drilled a lengthwise hole down through t' center o' t' balsa block. Arrr! Blimey! Then I cut t' block in half as before. Aye aye! Blimey! Ya scallywag! Blimey! Now at least I had a cavity t' start with, me bucko, matey, shiver me timbers, even though it be a bit smaller in diameter than a BT-55. Begad! Blimey! After layin' out the kite pattern and cuttin' off t' excess balsa, I started sandin' on t' body tube again. This time me efforts were workin' as planned. Aye aye! Blimey! Ya scallywag! Blimey! I be gettin' a piece o' balsa that would conform nicely t' t' diameter o' t' BT-55. Well, blow me down! Blimey! Satisfied with that effort, me bucko, t' next task was t' shape t' canopy. Blimey! Blimey! Try as I might, I just couldn't (or didn't want to) replicate the relatively complex shape o' t' original. Ahoy! 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, I glued t' canopy t' t' tube and used Fix-It epoxy clay t' blend t' canopy t' t' tube as best I could. Blimey! Durin' this time I was realizin' me finishin' skills needed much improvement. Blimey! I broke out me 8-year old pint can o' Sandin' Sealer and started applying. Arrr! Well, blow me down! I used some Fix-It t' fill some shrinkage holes in t' yellow glue fin fillets, which worked quite well.

Finishing:
After sealin' and primer, shiver me timbers, I painted t' red/white/blue scheme shown in t' early Estes catalogs. Avast, me proud beauty! Blimey! Ahoy! Blimey! T' canopy is gloss black. Avast! Blimey! Aye aye! Blimey! I don't have any decals for t' Star Blazer yet. Ahoy! Blimey! I might try Tango Papa. Avast, me proud beauty! Blimey! Avast, shiver me timbers, me proud beauty! Blimey! 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, matey, 3-color pattern on fins, and isolatin' t' black on t' canopy.

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

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

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

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