Introduction:
After gettin' back into rocketry via 3x18mm and 3x24mm Estes-que scratch-built rockets, I figured it be time t' move on up and try composite motors. Avast, me proud beauty! Econojets were t' best bet for t' short-term, me bucko, arrr, since I wasn't ready t' invest in a reload casing, me bucko, and they have a decent burn time and a rather unique louder-than-normal sound. Ahoy! T' original goal was t' aim for a design that would sneak under t' 16 ounce FAA notification limit, but I haven't strolled into t' local supermarket yet with t' rocket under me arm. Doesn't matter that much if it is over, ya bilge rat, since me limited club experience has been enjoyable so I don't plan on launchin' at t' local field any time soon.

Nose Cone:
Made from a $.99 foam cone at t' local fabric store. Begad! Haven't bothered with a drill lathe system yet. Avast! Results were 'good enough' for this proof-of-concept rocket. Covered it with three layers o' tissue paper/wood glue, matey, with a final layer o' wood glue t' seal it. Well, blow me down! Sanded, primed and sanded again. Depressions were then filled with some leftover whitewall mud and sealed with glue. Aye aye! Resulted in a heavy yet fairly smooth and strong nose cone 5.25" long, arrr, with 1.25" o' it bein' t' shoulder.

 Recovery System:
1/2 inch sewn flat nylon elastic cord from t' local fabric store, 4 feet o' it. Yes, I know t' cord is supposed t' be longer, but smaller versions o' t' same material worked fine on me clusters, me bucko, so I trusted me instinct on this one. Arrr! Well, blow me down! Mounted t' t' body via two wooden dowels that are glued through t' body tube. T' idea be t' have them 90 degrees from each other, but in me haste t' build, things got a little out o' alignment. Ya scallywag! Tied a loop in t' cord, then placed t' dowels through loop inside o' t' rocket. Parachute is composed o' two plastic layers from a garbage bag, 23 inches in diameter. Eight shroud lines composed o' a waxy version o' kite string, matey, which keeps tangles down, attach t' t' parachute via duct tape. Ya scallywag! T' 'chute is attached t' t' shock cord through a grommet in a folded over section, shiver me timbers, arrr, which was then layered with wood glue and tissue paper as well as CA. I was goin' t' use swivels t' attach t' parachute, matey, ya bilge rat, but decided against it. Ahoy! Just didn't trust t' ones I had on hand. Avast, me proud beauty! Well, blow me down! Nose cone is attached at t' end o' t' shock cord via tissue paper and wood glue, ya bilge rat, about 2.5 inches from t' parachute grommet.

Body Tube:
Grabbed t' parallel-wound tube at t' fabric store, me hearties, t' clerk gave me a rather odd look when I asked if I could have it. 39.5" long, 2.23" across and .125" thick. Begad! Blimey! It be longer, ya bilge rat, but for some reason I chopped off 8.5" o' it. Aye aye! Covered it in a layer o' watered down wood glue. Fin slots were started with a drill, then finished slowly with a keyhole saw and then 40 grit sandpaper until desired width be obtained.

 Motor Mount Tube:
Had t' make me own. Blimey! Took a garden tool handle, ya bilge rat, coated it with some oil, me bucko, and used a few grocery bags cut into 1" strips. Avast! Well, me bucko, blow me down! Once t' glue be tacky, added another layer o' paper wound diagonal t' t' first. Removed t' tube before it became attached t' handle.

 Fins:
I've got a huge amount o' balsa stock leftover from friends at school who were in t' architecture program. Well, blow me down! Decided t' go simple by gluin' two 1/8 pieces together, and goin' with three fins with a rectangular shape. Begad! Gave them an aerodynamic edge, matey, and covered them with 20 pound white paper and -you guessed it- watered down wood glue. They are 3.5" by 3", ya bilge rat, nay includin' t' t' amount that extends t' t' motor mount tube.
 

Fin Can Mounting:
Centerin' rings were made from 1/8 balsa stock soaked in wood glue. Was goin' t' double them up, matey, but they were a pain t' make, ya bilge rat, shiver me timbers, and they seemed strong enough. Aye aye! Fin edges attach t' both o' them. Blimey! Since I figured a strong bond t' t' centerin' rings was more important than internal fillets on t' fin body tube joint, I glued t' aft rin' in place before slidin' it into t' body tube. Avast! Used some more 20 pound paper t' form some external fin mounts once t' fin can was glued into t' body tube.

 Launch Lugs:
I wanted t' use a ¼ rod for this bird, so I grabbed two eyelets from t' workshop. Ya scallywag! Avast, me proud beauty! One is within a few inches from t' bottom, shiver me timbers, me bucko, and t' other is a few inches above t' CG. Arrr! Aye aye! Screwin' them into t' body tube then soakin' t' area around them with CA seemed t' work well.

 Painting:
I've never been a really big fan o' beautifully paintin' rockets since you never get t' see them up close while they are launching. Ya scallywag! As long as they have a decent gleam in t' sun, I'm happy. Avast, me proud beauty! I primed t' rocket and covered it with royal purple. I then tried a clearcoat which started t' strip off t' paint. Arrr! That's when I discovered t' whole problem o' mixin' enamel with lacquer paints, matey, tehehe. Ya scallywag! Never did get it perfect again, still have some crackin' on some o' t' fins. A coat o' auto wax later and Econoexpress was ready t' fly!

First Flight:
I finally got t' chance t' launch EconoExpress at CMASS's last sport launch o' t' year. Blimey! I loaded her up with an Econojet F20-4 at home, matey, with plenty o' tape as an external thrust rin' as well as motor retention. Two pieces o' Estes recovery waddin' were installed, as well as one piece around t' bottom o' t' parachute. Begad! Ahoy! Blimey! I was somewhat worried about t' over stability o' t' design, shiver me timbers, shiver me timbers, which at 3.6 calibers with a F20 loaded, matey, arrr, would make it fairly susceptible t' weather cocking, me bucko, especially at t' windy CMASS launch site. T' weather turned out t' be decent however, arrr, with moderate temperatures and light winds.

 Got t' copperhead installed, and absentmindedly flipped t' rocket back over before puttin' on t' rubber band. T' field then ate it. Begad! Aye aye! I be placed out on a high power pad, me hearties, since this be t' first launch o' t' rocket and I needed a 1/4 rod.

 Ignition be within a second o' t' button bein' pushed, shiver me timbers, and t' flight was nice and straight, with very little if any weather cocking. T' Econojet didn't disappoint, matey, plenty o' noise for an F! Ejection was a bit early, shiver me timbers, about 1200-1400 feet up, and then t' fun started. Arrr! Rocket did 5 t' 6 revolutions around t' now-opened parachute before finally settlin' down. Blimey! Everythin' held together though, and I recovered it a bit downrange in perfect condition.

 Conclusion:
I'm happy with t' results, 2 bucks (for t' foam and shock cord material) isn't all that bad for a rocket o' this size that can fly on Econojets. Aye aye! Goin' t' try out a F20-7 next time around, me bucko, shiver me timbers, matey, and then step up t' a G35-7. Hopefully I won't stress t' recovery system as much with these delays, me bucko, or so t' sims tell me. Begad! Heck, maybe I'll get somebody t' stick in a H125W!

As o' 01/12/00, EconoExpress has flown a total o' 3 flights. Avast! F20-7 is a little long but works fine, and a G35-7 really pushes it up there!