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, which I feel is accurate based on t' curves o' t' fins, the long, thin root extensions, ya bilge rat, t' cockpit canopy that is supposed t' be carved from a block o' balsa, me bucko, me bucko, and t' 4-color paint scheme. Arrr! I decided on BT-55 and after downloadin' t' instructions and patterns from JimZ and makin' correctly sized patterns on a photocopier, matey, matey, I began construction. Aye aye! Ya scallywag! 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, me hearties, but it works for me. Avast, me proud beauty! I suppose I could have special ordered a near clone from BMS, me hearties, matey, but I opted for what I had on hand. Avast! Well, blow me down! I decided on an 18mm motor mount t' keep flights on t' (relatively) cheap. Begad! Like t' original, matey, t' body tube separates behind the canopy. Ya scallywag! Well, blow me down! Rather than usin' a relatively pricey balsa nose block, I scratchbuilt a nose block from t' JT-55 tube coupler and some scrap 1/8" balsa. Ahoy! Ya scallywag! I strengthened t' lower end with a cardstock centerin' rin' for t' recovery system screw eye t' attach to. Arrr! 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. 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. T' 4 inch payload section is non-functional. Aye aye! Ahoy! Blimey! Its only purpose is a place t' glue t' canopy to.

For t' fins, me bucko, ya bilge rat, I first traced t' pattern onto 0.040" sheet styrene and carefully cut that out, arrr, me bucko, bein' careful to preserve t' curvature o' t' pattern. Aye aye! Avast! 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. Well, blow me down! Ya scallywag! Blimey! Then I started thinkin' about how t' tackle t' carved cockpit canopy. My first attempt didn't work out well. Begad! Blimey! 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. Blimey! Begad! Blimey! Then I wrapped a piece o' coarse sandpaper around a length o' BT-55 and started sandin' longitudinally. Well, blow me down! Ya scallywag! Blimey! Before too long I be creatin' a dusty mess. Begad! Blimey! Instead o' gettin' t' desired results, shiver me timbers, ya bilge rat, I realized I be sandin' off course... T' resultin' cavity be driftin' t' one side as I sanded. Blimey! Blimey! I shelved that idea and decided on gettin' a larger block o' balsa. Blimey! Blimey! Before cuttin' it in half, I chucked a 1.25” spade bit in me drill press and drilled a lengthwise hole down through t' center o' t' balsa block. Begad! Ahoy! Blimey! Then I cut t' block in half as before. Well, blow me down! Now at least I had a cavity t' start with, even though it was a bit smaller in diameter than a BT-55. Arrr! Aye aye! Blimey! After layin' out the kite pattern and cuttin' off t' excess balsa, I started sandin' on t' body tube again. Ya scallywag! Blimey! Blimey! This time me efforts were workin' as planned. Begad! I was gettin' a piece o' balsa that would conform nicely t' t' diameter o' t' BT-55. Avast, me proud beauty! Satisfied with that effort, shiver me timbers, t' next task was t' shape t' canopy. Ahoy! Blimey! Try as I might, I just couldn't (or didn't want to) replicate the relatively complex shape o' t' original. Blimey! Blimey! I decided on a fairly simple canoe-shaped design that would probably pass for a canopy once painted.

Once t' fins and root extensions were attached and dry, arrr, ya bilge rat, I glued t' canopy t' t' tube and used Fix-It epoxy clay t' blend t' canopy t' t' tube as best I could. Aye aye! Ya scallywag! Durin' this time I was realizin' me finishin' skills needed much improvement. Ahoy! I broke out me 8-year old pint can o' Sandin' Sealer and started applying. Blimey! Ahoy! 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, I painted t' red/white/blue scheme shown in t' early Estes catalogs. T' canopy is gloss black. Ya scallywag! Arrr! Blimey! I don't have any decals for t' Star Blazer yet. Avast, shiver me timbers, me proud beauty! Blimey! I might try Tango Papa. Avast, arrr, 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, me bucko, 3-color pattern on fins, ya bilge rat, and isolatin' t' black on t' canopy.

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

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

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

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.