Brief:
For a long time now, me bucko, me hearties, me favorite rockets have been military missiles. Begad! Blimey! I have built many in t' past and wanted t' build a HPR version o' t' Harpoon AGM-84. I decided t' scratch build, since thar were no kits t' fit t' bill, shiver me timbers, and designed a 4" 33% Scale Harpoon AGM-84. Ya scallywag! Blimey! T' rocket has a 38mm motor mount, 54" PML parachute, Nomex ® cloth, Keelhaul®©™ ® for shock cord and a detailed scale set o' decals.

T' body tube is made o' PML 4" Quantum tubing, arrr, shiver me timbers, which I had custom slotted and cut at t' factory. They did their usual great job, me hearties, ya bilge rat, and they followed me cutting/slottin' instructions t' t' tee! Hats off t' t' guys at PML. Begad!

This will be t' first t' be built in a series o' 4" models I have designed and are on t' buildin' board. Well, blow me down! I did check t' WPAFB Museum website and they have one o' every missile I have interest in on site, with the exception o' this one. Begad! Avast! For some reason, arrr, it couldn't be that this is primarily a Navy missile, I had a hard time findin' pics for it so I could do scale decals. Some good pics were found and I was able t' create some decals that are very close t' scale. Aye aye! Well, blow me down!

Construction:

Construction began by cuttin' t' 38mm motor mount tube t' 23.75". Ahoy! Ya scallywag! Then I measured and glued t' first centerin' ring, which be t' lower o' two rings for t' center fins. Ahoy! Arrr! Both sets o' fins are sandwiched betwixt centerin' rings. Next, I cut out the fins from t' RockSim pattern I printed out from t' design. Avast, arrr, me proud beauty! Usin' a Dremel, me bucko, asbestos cuttin' wheel, arrr, and a vacuum t' pull in t' dust while I cut, all four upper fins and four lower fins were cut with ease from t' G10 sheeting. They were final sanded on me table sander and now fit t' slots well. After cuttin' me own G10 fins, me hearties, I highly recommend this t' anyone who wishes to scratch build; it will save you a fortune over pre-cut fins and are very easy and fast t' make. Avast, me proud beauty!

T' four inch coupler be cut t' a length o' 7" and edges were sanded. Finally, I measured t' 1/2" thick by six inch centerin' ring, ya bilge rat, me hearties, which will extend past t' aft o' t' body tube as a boattail. Well, blow me down! It be reduced t' 4" in diameter, ya bilge rat, so it would fit flush with t' outside o' t' body tube. Avast, me proud beauty! Aye aye!

A centerin' ring was mounted t' t' motor mount tube and it was installed in t' body tube after roughin' it up with sandpaper. Arrr! This CR sits just below t' slots for t' center fins. Blimey! A second CR was installed just above t' lower fin slots. Blimey! Ahoy! Fin edges were rounded and surfaces were roughed up and t' lower fins were glued in place to the motor mount and upper CR. Ahoy! Also, me hearties, arrr, me bucko, t' lower fins were glassed from t' motor mount, matey, shiver me timbers, up t' inside o' each fin and across t' inside o' t' body tube area. In addition, shiver me timbers, t' lower centerin' rin' be installed flush with t' body tube and against t' bottom o' t' lower fins. Arrr! Aye aye! Finally, t' lower transition was sanded t' angle t' bottom edge for t' "transition" look. Well, blow me down!

I worked on the ply 1/2" thick tail transition piece. Ahoy! 3 holes were drilled through it to accept t' 8/32 sized bolts for t' PML motor retainer. Blimey! I used a 1/2" drill bit t' open a recess in t' top side o' t' transition, me bucko, then carve it out usin' a dremel and small sandin' tube so t' blind nuts would sit recessed inside this "well". Avast, me proud beauty! Begad! This was necessary so t' piece could be glued flush t' t' bottom CR on t' model. Ya scallywag! Next, ya bilge rat, ya bilge rat, I placed some glue inside t' recess and installed t' three blind nuts, me bucko, then tested for a flush fit. Ya scallywag! Finally, me hearties, the blind nut threads were filled with wax, shiver me timbers, then t' excess wax was shaved flush and I epoxied t' transition t' t' bottom o' t' rocket and motor mount. Upper fins were next; each canard fin was glued t' t' motor mount and lower centerin' ring. Aye aye! I also took t' final centerin' ring, t' one that would fit on top o' t' center fins and drilled two holes, then mounted t' Stainless Steel 3" wide U-Bolt for t' shock cord. Begad!

Next, arrr, I glassed each canard fin inside t' t' motor mount and inside body tube, shiver me timbers, then glued in the last centerin' rin' with t' U-Bolt as a top cap t' t' center fins. Blimey! The coupler was installed next, followed by t' upper section o' body tube. Begad! Begad! I ran maskin' tape around t' seam t' help keep both upper an lower body tubes in alignment with each other until t' glue set. Avast! Arrr! I have seen where a coupler has some play and can leave t' joint a bit "out o' round", which leaves a little overlap betwixt t' tubes. Usin' several wraps o' maskin' tape kept it in alignment and t' tape easily pulled off once t' glue has set. Avast! Ya scallywag! T' coupler adds strength t' t' centerin' rin' since it is holdin' t' rin' down atop the center fins. This method was used t' insure it had a solid anchor since it has to handle t' stress o' deployment.

Once everythin' had dried, I started glassin' t' lower fins. Aye aye! At this time, one o' four sides is glassed. Arrr! While t' epoxy be still curin' for t' cloth, I cut t' lower 1/2" launch lug t' a length o' 2 1/2", me hearties, then epoxied it between t' lower fins, 1" from t' body tube bottom. Arrr! Next, ya bilge rat, I finished fiberglassin' t' fins, then added fillets t' t' upper canard fins and mounted the upper launch lug. Avast, me proud beauty! Begad!

T' upper fillet sandin' be completed. Well, blow me down! In addition, t' seam be sanded smooth and lower fillets were sanded, but t' cloth edge still needs blended to the body tube. Arrr! Also, t' bottom o' t' boattail plywood was glazed with epoxy. Begad! Ahoy!

Some work be done on t' Nosecone; if you all have never had t' pleasure of usin' t' RGM Nosecones, you are really missin' out! T' quality is fantastic with a SEAMLESS design, yes, me bucko, I said seamless. It was like a rocketeers dream come true! T' nosecone is made from resin and cloth and is yellow in color, arrr, similar t' t' resin model airplane and boat kits you can buy. T' quality is excellent, matey, matey, with a good fit at t' base, matey, me hearties, a molded-in U-Bolt and ultra smooth finish, right out o' t' box. Begad! Avast, me proud beauty! They are t' date t' only "round" Nosecone I could find in t' 4" version. Aye aye! As a final FYI, Ross at Magnum told me that t' gentleman at RGM lays up all these cones one at a time, by hand! With a price o' $29.95, matey, me hearties, they are about $10 more than a plastic ogive nosecone, but you get what you pay for and it's worth it!

T' nosecone be lightly sanded and washed t' remove any release agents, then one coat o' primer be applied, which came out nice. Well, blow me down! No problems were found with t' primer stickin' t' this resin Nosecone. Well, blow me down! Arrr!

T' glassin' in t' lower fin area was sanded and blended usin' a dremel power sander, arrr, then touched up by hand with 100 grit sandpaper. Ya scallywag! Plugs were inserted into t' lugs so they would nay get painted inside, then t' holes for the motor retainer were re-drilled out and blind nuts were tapped with an 8/32 tap t' remove t' wax used t' seal t' threads from epoxy. Aye aye!

Finishing:

Three coats of white Krylon primer were applied t' t' body, followed by two coats o' gray Krylon primer. Begad! Blimey! Pinholes were filled next, me hearties, then sanded with 220 grit sandpaper. Two more coats o' gray primer were applied, me bucko, shiver me timbers, followed by 3 coats o' white primer. I am lettin' t' body tube dry overnight and will wetsand it tomorrow, then apply more primer if necessary and t' colors. Ahoy! Blimey! Finally, arrr, me hearties, t' nosecone was given about 6 coats o' primer, then wetsanded with 320 grit wet/dry sandpaper; 3 more coats o' white primer were applied t' t' nosecone and left t' dry overnight. Arrr! Blimey! Avast, me proud beauty! Blimey!

T' model was wetsanded with 400 grit wet/dry paper, me bucko, matey, then 600 grit. Avast, me proud beauty! Avast! I painted t' Nosecone first, with 4 coats o' Krylon Glossy White spray paint. Next, t' body tube be painted, me hearties, also with four coats. They are both dry, shiver me timbers, arrr, but I am lettin' it set overnight before paintin' t' stripes. Begad! In t' interum, ya bilge rat, I am workin' on some scale decals for t' Harpoon, shiver me timbers, but need pictures...I don't have any good pictures o' t' letterin' for different sections. Avast! Ahoy!

T' Harpoon was weighed at our first HPR launch ever for our Cincinnati NAR club. Begad! I almost fell over when I saw, but knew it was goin' t' be heavy, me bucko, as I added most o' t' ballast in birdshot that Ken Parker gave me when I was in NC this past summer. Avast! It weighed in at 6lbs 7.8oz without motor!!!!!

I almost died...goin' t' have t' re-do all me sims t' see if it can handle an I211 because, even though she isn't painted, arrr, me hearties, me hearties, she was goin' t' fly at our HPR Launch, which is a two day event. Blimey! It will be like flyin' a heavy torpedo, ya bilge rat, which is what it represents anyway, matey, so what t' heck. Aye aye! Well, ya bilge rat, blow me down!

Flight:
I had two launches usin' an I211W for t' Harpoon's maiden flights. Begad! T' first flight was perfect; awesome power and came off t' pad stable, lifted well and deployed right at apogee. Avast! T' rocket landed safely and t' 54" PML parachute I used worked well and was unmarred due t' t' use o' a Keelhaul®©™® cloth. Aye aye! However, arrr, t' second launch had an early ejection.

Recovery:
T' nosecone tore off t' cord and plummeted t' t' earth, me hearties, yet was recovered after diggin' it out, me hearties, with only scratches. T' rocket landed right on top o' a tree, matey, me hearties, arrr, about 40 feet up. Well, blow me down! I spent 7 days tryin' t' retrieve it before it came out of t' tree. Ya scallywag!

T' rocket suffered a minor zipper in t' upper body tube, which was easily repaired. Begad! I used Keelhaul®©™ ® shock cord for t' model and it came out with no marks at all. Arrr! Blimey!

Summary:
T' tube be replaced and I applied all decals for t' Harpoon. Ya scallywag! It really looks good now and will fly again soon. Ya scallywag! Anyone interested in military missiles should consider buildin' one o' these. Ahoy! Aye aye! T' file has been uploaded t' EMRR and it's a great flier and real looker. Begad! Avast, me proud beauty! Moreover, shiver me timbers, you can have a set o' decal files with all t' work done simply by sendin' me an email or visitin' Jim Ball's Scale Data website, matey, shiver me timbers, ya bilge rat, which should have me decals uploaded soon. Ahoy! Begad! Since t' design and decals are complete and it's a good flier, ya bilge rat, most o' your work is already done, so take t' leap and impress t' crowd with this AGM-84 Harpoon. Well, blow me down!