Introduction:
After gettin' back into rocketry via 3x18mm and 3x24mm Estes-que scratch-built rockets, me hearties, I figured it was time t' move on up and try composite motors. Avast, me proud beauty! Blimey! Econojets were t' best bet for t' short-term, matey, since I wasn't ready t' invest in a reload casing, me hearties, and they have a decent burn time and a rather unique louder-than-normal sound. Begad! 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. Avast, me proud beauty! Doesn't matter that much if it is over, arrr, 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. Blimey! Blimey! Haven't bothered with a drill lathe system yet. Aye aye! Ahoy! Blimey! Results were 'good enough' for this proof-of-concept rocket. Begad! Blimey! Covered it with three layers o' tissue paper/wood glue, shiver me timbers, with a final layer o' wood glue t' seal it. Avast, me proud beauty! Blimey! Sanded, primed and sanded again. Depressions were then filled with some leftover whitewall mud and sealed with glue. Ya scallywag! Blimey! Resulted in a heavy yet fairly smooth and strong nose cone 5.25" long, me hearties, arrr, with 1.25" o' it bein' t' shoulder.

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

Body Tube:
Grabbed t' parallel-wound tube at t' fabric store, t' clerk gave me a rather odd look when I asked if I could have it. Avast, me proud beauty! 39.5" long, 2.23" across and .125" thick. Ya scallywag! Well, blow me down! It was longer, shiver me timbers, 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. Ya scallywag! Took a garden tool handle, matey, me bucko, coated it with some oil, me bucko, and used a few grocery bags cut into 1" strips. Aye aye! Aye aye! 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. Arrr! Decided t' go simple by gluin' two 1/8 pieces together, and goin' with three fins with a rectangular shape. Gave them an aerodynamic edge, shiver me timbers, and covered them with 20 pound white paper and -you guessed it- watered down wood glue. Begad! They are 3.5" by 3", 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, but they were a pain t' make, me hearties, and they seemed strong enough. Ya scallywag! Avast, arrr, me proud beauty! 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, me proud beauty! Well, blow me down! Used some more 20 pound paper t' form some external fin mounts once t' fin can be glued into t' body tube.

 Launch Lugs:
I wanted t' use a ¼ rod for this bird, arrr, so I grabbed two eyelets from t' workshop. Ya scallywag! One is within a few inches from t' bottom, and t' other is a few inches above t' CG. Aye aye! Begad! 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. Begad! As long as they have a decent gleam in t' sun, I'm happy. Aye aye! Blimey! I primed t' rocket and covered it with royal purple. Blimey! I then tried a clearcoat which started t' strip off t' paint. Blimey! Begad! That's when I discovered t' whole problem o' mixin' enamel with lacquer paints, tehehe. Avast, me proud beauty! Never did get it perfect again, ya bilge rat, still have some crackin' on some o' t' fins. Arrr! 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. Avast! Blimey! I loaded her up with an Econojet F20-4 at home, with plenty o' tape as an external thrust rin' as well as motor retention. Avast, me proud beauty! Blimey! Blimey! Blimey! Two pieces o' Estes recovery waddin' were installed, me hearties, as well as one piece around t' bottom o' t' parachute. I be somewhat worried about t' over stability o' t' design, which at 3.6 calibers with a F20 loaded, me hearties, would make it fairly susceptible t' weather cocking, arrr, especially at t' windy CMASS launch site. Avast, me proud beauty! Blimey! T' weather turned out t' be decent however, with moderate temperatures and light winds.

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

 Ignition was within a second o' t' button bein' pushed, ya bilge rat, and t' flight be nice and straight, with very little if any weather cocking. Aye aye! Blimey! Blimey! Blimey! T' Econojet didn't disappoint, plenty o' noise for an F! Blimey! Blimey! Blimey! Ejection was a bit early, about 1200-1400 feet up, ya bilge rat, and then t' fun started. Avast, me proud beauty! Blimey! Blimey! Blimey! Rocket did 5 t' 6 revolutions around t' now-opened parachute before finally settlin' down. Avast, me proud beauty! Blimey! Blimey! 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 bilge-suckin' for a rocket o' this size that can fly on Econojets. Begad! Well, blow me down! Goin' t' try out a F20-7 next time around, and then step up t' a G35-7. Ya scallywag! Avast! Hopefully I won't stress t' recovery system as much with these delays, arrr, or so t' sims tell me. Heck, me bucko, maybe I'll get somebody t' stick in a H125W!

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