Pre-Construction Plans

1. Drill 5/16 hole into all 3 G-10 Fiberglass Centering Rings for placement of 5/16 threaded rods.  Each area in front and behind the centering rings (threaded rods) will be secured with 5/16 steel washers and 5/16 hex nuts.  All will be secured with 5-Min epoxy.  All of this is for test fitting right now—will be epoxied in place at a later step.

2. “2” 5/16 Steel U-Bolts will be secured into the top centering ring of the motor mount on opposite sides using 5-min epoxy on the threads of the hex nuts and washers to prevent separation in flight.  This area will be described in greater detail in the recovery section of this manual.  Careful measurement of the placement of the threaded will take place to make sure I don’t compromise the positioning of the fins.

3. Motor Retention Assembly:  Aft end G-10 Fiberglass Centering Ring will be constructed with a 98MM Aero Pak Motor Retainer. I will carefully mark and drill each of the 12 holes and carefully epoxy (5-min) and screw each of the 12 hex nuts through the motor retainer into the fiberglass centering ring.  On the opposite side of the aero-pak motor retainer I will fiberglass/epoxy the back of the hex screws for additional strength and security after fins are assembled and fiberglassed securely to the motor tube and opposing fins.

4. With regards the pre-slotted fin slots I will need to lengthen them probably by 3/16 of an inch on top to accommodate the fins more precisely.  This will be accomplished with the use of a dremel saw.  Also, I will dremel away the bottom of each pre-slotted area to be able to remove the whole motor mount with fins attached for the fiberglassing job mentioned below.

5. A G-10 Fiberglass Centering ring will be epoxied in place just above the fins but placed
carefully so that the fins will slip in easily through the fin slots.  Measurement of this will be precise as I will “tack-on” the fins using 5-Min. Epoxy through the fin walls onto the motor mount and place the upper centering ring on top of the fins.

6. Once the epoxy on the fins are dry, I will entirely remove the whole “fin-can” assembly I mentioned above. 

7. At this point will permanently place the threaded rods through the drilled holes and attach the steel washers and hex nuts at the appropriate time.  Each will be secured with 5-min epoxy to prevent separation during flight.

8. Using 5-oz fiberglass cloth I will cut a precise strip to fit over the root edge (1-inch up on fin) and then over the motor mount and up onto the next set of fins.  Fiberglassing will continue over all 3 sections of fin attachment.

9. Final Centering Ring with U-Bolts will be secured on top of the motor mount,  All joints  and attachment points will be secured using West Systems 105 Epoxy Resin, West Systems 205 Hardener, and West Systems 406 Colloidal Silica.

10. Fin can assembly will now be placed back into the booster section of the rocket.  I want to now epoxy the inside area of the booster secton where the fins have come through the body tube.

11. The first of 2 Extreme Rail Buttons will be secured this time in between two fins.  Extra security will be obtained by screwing not only through the rail button/body tube but also into a ¼ plywood piece and a hex nut to hold in place firmly.  The inside will also be epoxied for extra strength.

12. Securely place the Motor Retainer/Aft Centering Ring into final position and secure firmly with the West Systems Epoxy.

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