In this segment, Chris Chianelli begins the process of assembling the StormCaster by Estes (TM), a skill-level 1 model rocket suitable for novice rocket builders. Though this is a fairly sizable rocket (figure A), it is still a beginner-level model. It should be noted that size and skill-level in model rocketry are independent factors. Larger models may be more complex than smaller ones, or the reverse can be true. StormCaster Assembly, Part 1 -- Engine Assembly
Materials (figure B): Fine grit sandpaper
Hobby knife
Small hobby paintbrushes
Spray primer paint
White and yellow spray enamel paint
Sanding sealer
CA (cyanoacrolate) glue
Carpenter's glue
Masking tape
Ruler
3 long shank cotton swabs
Scissors
Important: This demonstration shows provides some of the basic information for assembly and operation of this particular model rocket. There are variations in assembly for each particular model. Read and carefully follow the manufacturer's instructions that come with yours, whether it is this particular model or another. Additional information about assembly as well as launching, troubleshooting and fine-tuning the model can be found in the manufacturer's instructions.
Steps: - Within the engine-mounting tube, a ring known as the engine stop (figure C ) is inserted and mounted in order to hold the engine components in position.
- Since the engine stop must be mounted within the tube at a specific point, a spacer (figure D) is used for positioning the stop. (In the case of our model, the engine block must be positioned 2 inches from the end of the tube.) Following the manufacturer's instructions, make a mark on the spacer 1/2-inch from the end. This mark will be used as the reference for positioning the engine stop.
- Use a cotton swab to apply glue to the inside of the engine-mounting tube to secure the engine stop. Again, since the engine stop must be mounted at a specific point within the tube, mark the distance on the stem of the cotton swab (figure E) so that the glue can be applied at the correct location within the tube.
- With the reference mark made, apply glue around the inside of the tube using the mark as a guide.
- Insert the engine block into the tube, and push it in to the designated position -- using the spacer and the reference mark as a guide (figure F).
- Next, install the engine-retaining hook (figure G). This metal hook is what keeps the engine from coming out of the tube during the parachute-ejection stage of the flight. The hook is held in position on the outside of the tube by means of a retaining sleeve.
- In the case of the StormCaster, a mark is made at 2-1/4 inches from the end of the tube, and a slit is made in the tube using a hobby knife (figure H).
- With the slit made, insert the upper end of the hook through the outside of the tube, apply some carpenter's glue to the outside of the tube, and slide the hook-retaining sleeve into position (figure I).
- Two adapters are placed on the outside of the engine tube. The adapters fit the inside diameter of the rocket-body tube. Place the first adapter on the lower end of the engine-mounting tube, and secure it using a small amount of CA glue (figure J).
- Place the second adapter ring 1/2-inch from the other end of the engine-mounting tube and secure it in the same manner with CA glue (figure K).
- The engine-mounting tube is now mounted inside the lower section of the rocket-body tube. Spread a small amount of carpenter's glue inside the rocket body tube, and insert the engine-mounting tube according to the manufacturer's instructions (figure L).
- Using a ruler or straight-edge as a guide, insert the engine-mounting tube until it's end is perfectly flush with the end of the body tube. The engine hook should extend beyond the end of the tube, and should be centered between the mounting slots for the rocket fins (figure M).
- Using a long-handled cotton swab, apply some glue to the upper adapter to secure it inside the body.
- Next, follow the manufacturer's instructions for gluing the upper and lower portions of the main rocket-body together.
- With the rocket-body assembled, the launch guide lugs can be attached to the outside. It's critical that the two guides be lined up precisely with each other on a single, straight line. Use a straight edge to draw a perfectly straight line along the outside of the body, lined up with the location of the engine-retaining hook (figure N).
- Attach the two launch guides -- lined up with each other along the reference line -- using CA glue (figure O).
- With the engine mounted and the lugs in place, the fins can be prepared for installation. Lightly sand the fins before removing them from the die-cut sheet.
- Once they've been sanded, remove the individual fins from the sheet. Sand the edges of the fins using the fine-grade sandpaper. To save time, hold all of them together, aligned in the same way, so you can sand all of the edges together (figure P).
- After the surfaces and edges have been sanded smooth, apply some sanding sealer to the wood fins (figure Q). You may want to repeat the process of sanding and sealing several times before applying any paint.
In the segment that follows, the StormCaster assembly is completed, including installation of the fins, painting the rocket and installation of the parachute.
RESOURCES :
Model rockets by Estes
Estes Industries
Penrose, CO 81240
Phone: 719-372-6565
Email: www.estesrockets.com
Handbook of Model Rocketry
Model: 0471593613
Author: G. Harry Stine
John Wiley & Sons
Somerset, NJ 08875-1272
Phone: 732-469-4400
Fax: 732-302-2300
Email: compbks@wiley.com
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