------------------------------------------------------------------------------------------- GENERAL ASSEMBLY ------------------------------------------------------------------------------------------- 1. READ THESE INSTRUCTIONS COMPLETELY BEFORE STARTING! Some of the assembly of this model requires that events be carried out in a specific sequence, otherwise the components may not contribute fully to the strength of the complete structure. 2. Assemble six (6) engineering pods using 1 each BNC-20AZ nose cone, BT-20DJ body tube, and BNC-20L tailcone. Set aside to dry. 3. Using the fin templates from the Discrete Parts sheet, cut six (6) of each piece from BFS-40 sheet stock. There are two (2) pieces to each fin. 4. Assemble the fins on a flat surface covered with a piece of wax paper. Use weights and clamps to maintain alignment while drying. Round the leading and trailing edges of each fin, but not the outer tip or root edges. 5. Mark one of the two BT-55 tubes for six (6) fins, 60 degrees apart. Draw lines the full length of the tube at each mark. Mark a seventh line halfway between two of the fin lines on this tube, full-length of the tube, for the two (2) launch lugs. 6. Thread the screw eye into the base of the BNC-55F nose cone. Carefully reverse-thread the screw eye out and force glue into the hole. Apply glue to the threads of the screw eye, then rethread the screw eye into the hole. Set aside to dry. ------------------------------------------------------------------------------------------- MOTOR CORE AND STUFFER TUBE ASSEMBLY ------------------------------------------------------------------------------------------- 7. Draw lines around the BT-50H motor core 0.75" from each end. Slip two (2) CR-5055 rings onto the tube, and push these in between the lines. Slide the rings outward toward the lines, until the rings just touch the lines. Apply a bead of glue on both sides of the rings and set aside to dry. 8. Draw lines around the BT-50 stuffer tube 0.75" from one end, and 6" from the other end. Slide two CR-5055 rings onto the tube at the opposite end from the 0.75" line. Slide one ring down to the 6" line, and slide the other ring back to the edge of the tube. Apply a bead of glue on both sides of the rings and allow to dry. 9. Draw a line around the JT-50C coupler at its midpoint. Apply glue inside one end of the BT-50H core, and insert the coupler until the edge of the tube touches the line. Do not push the coupler any farther. Allow to dry. Slide the CR-2050 ring into the opposite end of the core, to a depth of 6" from the bottom edge. Glue this ring in place from the front of the core tube. Set aside to dry. ------------------------------------------------------------------------------------------- MAIN BODY ASSEMBLY ------------------------------------------------------------------------------------------- 10. Slide the BT-50H core coupler-end-first into one end of the marked BT-55 body tube, until the bottom-edge of the core is even with the bottom-edge of the body. Glue this in place and set aside to dry. 11. Draw a line around the midpoint of the JT-55C coupler. Apply glue inside one end of the unmarked BT-55 tube, and slide this coupler into the tube until the edge of the tube touches the line. Set aside to dry. 12. Slide the long stuffer tube into the unmarked body tube from the end opposite the coupler, no-ring-end first. Pull this end of the stuffer through the coupler area until the ring at the 6" line touches the back of the coupler. Do not glue at this time. 13. Slip the long stuffer onto the coupler end of the core tube, then push the coupler end of the upper body tube into the lower body tube, allowing the stuffer to slide upward freely as the tubes are brought together. Carefully, apply glue to the upper ring-body joint in the upper body tube, and allow to dry completely before proceeding to the next step. 14. Separate the two body tubes. Apply glue to the lower ring-body joint in the upper body tube, and allow to dry completely. 15. Slide the last CR-5055 ring onto the exposed end of the stuffer tube, and align with the line at 0.75". Apply glue to both sides of this joint and allow to dry. 16. TAKE NOTE -- APPLY GLUE TO THESE THREE LOCATIONS IN ONE CONTINUOUS MOTION, WITHOUT PAUSING. THIS IS A VERY IMPORTANT SET OF GLUE JOINTS. (1) Using a long dowel or a long-handled paint brush as a glue applicator, apply a layer of glue inside the lower body tube about 8" down from the top end of the tube. (2) Apply glue to the inside of the bottom end of the stuffer tube. (3) Apply glue to the exposed surface of the JT-55C coupler. Slide the two halves back together, carefully aligning the stuffer tube onto the core coupler, and the large coupler into the lower body tube. Allow these joints to dry completely before continuing to the next step. ------------------------------------------------------------------------------------------- FINAL ASSEMBLY ------------------------------------------------------------------------------------------- 17. Attach the fins to the body on the fin position lines, even with the rear of the tube, using Stine's double-glue technique. Hold the fins in alignment while drying with jigs, clamps, and weights. 18. Draw one line on each of the six pods, lengthwise, from nose cone tip to tail cone tip. 19. Attach each pod to a fin, with the BNC-20AZ to the front and the BNC-20L to the rear. The fin is contoured to fit the BNC-20L. Allow each pod to dry completely before moving to the next pod, or the next step. 20. Attach the two launch lugs to the lower body tube on the lug line, with one lug even with the bottom of the tube, and the other lug even with the top edge of the lower body tube (at the joint line between the two body tubes). Allow these to completely dry. 21. Assemble the two parachutes, and attach a swivel to each set of shroud lines. Attach these swivels to the screw eye in the base of the BNC-55F nose cone. 22. Attach the shock chord to the inside-top of the upper body tube using a folded-paper mount, at least 2" down from the edge. When dry, attach the free end of the shock chord to the third swivel. Attach the swivel to the nose cone screw eye. 23. Finish the model as desired, with a final clear coat of acrylic to seal the paint and any decals that have been applied. 24. This model can allow for motors that are up to 200mm in length, 24mm in diameter. You will need to locate spacers (T-50 coupler stock) of the nescessary length to fill up the space between the engine block and the top of the selected engine, and which allows at least 1/4" of the engine to remain outside the tube.