Brief:
This is an upscale o' t' classic Estes kit, t' USS Andromeda.

Construction:

• 4" Tubes: LOC Kraft
• 3" Tubes: PML Phenolic
• "Conduit Dowels": 74" 1/2" Oak Dowels
• "Conduit Stand-Offs": 3/8" 7 ply bud Nosen
• Main Fins: 1/2" 12 ply
• "Ram Tube" fins: 3/8" 7 ply Bud Nosen
• Ram Tubes: 4" LOC Kraft
• Small outboard fins: 1/4" 5 ply Bud Nosen

I didn't do a very good job documentin' t' construction. Ya scallywag! Avast, me proud beauty! I didn't think of it until I be deep into t' project. Blimey! Ya scallywag! I downloaded t' original plans from Jim Z. Arrr! There be a problem with t' scale when designin' t' parts. Aye aye! Arrr! T' 4" tubin' scaled out t' 4.16x while t' 3" tubin' scaled t' 4.10x. Blimey! Arrr! Most of the rocket was designed usin' t' 4.16x scale. Ahoy! Some o' t' parts had t' be 4.10x while I compromised in some places usin' 4.13x. This kept t' whole package as proportionally close t' t' original as possible. Ya scallywag!

I waited until t' last possible moment t' chose t' motor size. Arrr! I even painted most o' it before choosing. Blimey! T' reason for this be weight. Well, arrr, blow me down! I wanted to know t' exact weight o' t' finished rocket. Blimey! Avast, me proud beauty! T' large fins will experience a great deal o' torque durin' t' initial thrust. Begad! Aye aye! I wanted t' choose a motor that would have enough power for a safe flight, arrr, me bucko, but nay so much that t' g force would tear it apart. Aye aye! Avast, me proud beauty! Each step o' t' way me thoughts were t' keep it as light as possible without sacrificin' strength. Begad!

It be a challenge makin' t' main fins. Begad! Ellipses can be hard t' upscale without pluggin' multiple coordinates into a CAD program. Aye aye! T' guys in the engineerin' department have been busy, ya bilge rat, ya bilge rat, me bucko, so I opted for an easier way out. I printed t' plans from Jim Z onto clear overhead projector paper. Avast! I measured the root o' t' fin and placed that dimension on a piece o' draftin' paper. Begad! I then projected t' image onto t' draftin' paper so that it lined up with the upscale dimension on t' paper. Well, blow me down! T' projector was squared and leveled several times. Well, blow me down! Ya scallywag! I then simply traced t' projected image onto t' paper, cut it out, and traced it onto t' wood. Well, blow me down! Avast!

T' three rings on t' fin can act like exterior centerin' rings. Countin' these, matey, t' main fins are mortised with 7 centerin' rings. Blimey! Begad! T' 3" tube goes all t' way t' t' bottom so thar is only 1/2" o' fin "through t' wall". Arrr! Well, blow me down! I tried t' compensate by ID fillets & epoxy rivets. T' entire ID o' t' 4" tube is coated with epoxy and t' CR/fin joints have 1/4" o' epoxy poured on them, all sides. All epoxy betwixt t' 4" and 3" tubes are 2 hour slow cure. Avast! In all, the fins are attached with 9 oz o' 2 hour epoxy. Ya scallywag! Another bit o' security was several (probably 30 or 40 in each fin) 1/4" deep 1/16" holes drilled into t' fin roots t' act as epoxy rivets. Aye aye!

T' small outboard fins are attached with four 2 1/2" long 1/8" diameter oak pins. Avast, me proud beauty! Begad! Each pin goes through t' main fin and into each fin 1". Well, blow me down! 2 hour epoxy here too. Well, blow me down! Blimey! Again, another bit o' security be several 1/8" deep 1/16 holes drilled into t' fin roots t' act as epoxy rivets. Begad! Arrr!

T' conduit dowels were secured t' t' main fins with a kind o' mortise and tennon thing. T' depth o' t' mortise is about 1 /1/2". Avast, me proud beauty! Blimey!

I just had t' throw this in for good measure: Nay countin' any internal fillets, ya bilge rat, t' total length o' t' fillets on this puppy is 41.6 feet. Well, blow me down!

Finishing:
Finishin' t' rocket be one o' the more difficult tasks. T' majority o' t' "decals" were made form Super Monokote. Ya scallywag! Jim Z made some upscale "paint masks" for me. At first, I tried t' rubber cement/paint mask thing. Ya scallywag! What a disaster! T' paint bled like a stuck pig. Blimey! Blimey! So I 86'd t' paint mask idea and cut out t' decals with orange Monokote underneath. Well, blow me down! T' white be done t' same way but I used sticker material. Ya scallywag! T' paint was Rustoleum satin black.

T' three "coolin' rings" were painted white in t' '75 & '76 Estes catalogue. They were painted black in t' '77 through '82 catalogues. Avast! I opted t' paint them white t' add contrast in t' area. Aye aye!

Flight:
Well, me hearties, shiver me timbers, I sent t' Andromeda up on a J350. It left t' pad with authority and flew perfect. Blimey! It arched over at apogee and t' deployment came out perfectly timed.

Recovery:
Wait... Well, blow me down! Ya scallywag! What's this? T' chute is tangled! T' darn thin' backward slid all the way in at a pretty good clip. Avast, me proud beauty! (That's what 16 pound rockets do ya know.) It hit the ground with a thud. Avast, me proud beauty! Nay pretty. Begad! With me heart stopped, and me stomach in my throat, ya bilge rat, I told me self "its only a rocket, right?" I am in the process o' rebuildin' it right now and should have it ready t' fly again at the May 11 NEPRA launch. Arrr! Ahoy!

Summary:
Wow! this was much more work then I had anticipated.

Other:
Upscalin' old Estes kits is a great way t' build HPR and remember your youth at the same time. Avast! Well, me bucko, blow me down! Here is a video. It's a bit big at 2.3 megabytes.