BARCLONE "Centaur" -- Sheet Three of Three CONSTRUCTION --------------------------------------------------------------------- 1. Assemble two (2) 24mm "E" motor mounts, using the instructions for the Medium 24mm "E" Motor Mount. 2. Mark one of the two 5" BT-60R tubes for three fins and draw lines the full length of the tube at these marks. This tube will become the booster. 3. Mark the 18" BT-60 tube for three fins, and draw lines up from the bottom of the tube for a distance of 5". This is the sustainer. 4. Slip the JT-60 coupler into the bottom of the sustainer and into the top of the booster. Rotate the booster until the lines marked on it are exactly half-way between the lines on the sustainer. Mark the sustainer at a location half-way between one of the lines on the booster and one of the lines on the sustainer. Draw a line the full distance of the sustainer at this mark for the launch lugs. Mark this line 5" up from the bottom of the tube, and 5" down from the top. 5. Remove the coupler from the two tubes. Mark the coupler 3/4" from one end and draw a line completely around the coupler. The two ends should be equal. Apply a thin layer of glue around the coupler on one side of the line, and also apply a thin layer of glue on the inside surface of one end of the booster tube for a depth of no more than 1/2". Push the glued end of the coupler into the glued end of the tube until the line on the coupler is just HIDDEN by the booster tube. This end of the booster is now the FRONT. 6. Mark the NB-60 bulkhead 3/4" from one end and draw a line completely around the bulkhead. The two ends should be equal. Apply a thin layer of glue to the bulkhead on one side of the line, and also apply a thin layer of glue to the inside of the remaining 5" BT-60R for a depth of 1/2". This tube now becomes the payload section. Press the glued end of the bulkhead into the glued end of the tube until the line on the bulkhead is just HIDDEN by the tube. 7. Thread the SE-3 screw eye into the center of the base of the bulkhead, twist the screw eye back out, and force glue into the hole. Thread the screw eye back into the hole. 8. Apply a generous layer of glue 2" inside the booster tube from the rear, and slowly insert one of the two motor mount subassemblies, also from the rear of the booster tube. Continue pushing the mount forward until the bottom of the engine hook is flush with the bottom edge of the booster tube. Apply a bead of glue completely around the base of the rear CR-5060 where it contacts the inside diameter of the booster tube. Set aside to dry completely. 9. Apply a generous layer of glue 2" inside the sustainer tube from the rear, and slowly insert one of the two motor mount subassemblies, also from the rear of the sustainer tube. Continue pushing the mount forward until the bottom of the engine hook is flush with the bottom edge of the sustain tube. Apply a bead of glue completely around the base of the rear CR-5060 where it contacts the inside diameter of the sustainer tube. Set aside to dry completely. 10. Cut the nine (9) pieces of the fin from BFS-40 sheet balsa stock, using a fresh #11 blade and a metal straight edge, slightly OUTSIDE the lines of the patterns. Sand the ROOT EDGES of each piece FLAT and test- fit them to each other. Carefully trim and flat-sand each joining edge until the pieces fit together correctly. Dry-fit the pieces together and flat-sand all of the root edges at one time before gluing. 11. Lay out a piece of wax paper onto a solid, flat surface for gluing the fin pieces together. Use clamps or heavy weights to keep the pieces flat with respect to each other, and to keep the pieces from moving around before the glue sets up. Use the metal straight edge to align the root edges of each fin unit while laying out the pieces. Let these fins dry completely. 12. Sand all of the edges of the six (6) fin units to a rounded shape EXCEPT for the ROOT EDGES, which should already be flat. Attach three fin units to the booster, in a SWEPT-FORWARD attitude, using the double-glue method found in Stine's Handbook. Attach the remaining three fins to the sustainer in a SWEPT-BACK attitude using the same double-glue method. Use clamps and pre-set angle jigs (can be made from scrap balsa) to hold the fins in proper 120-degree alignment to each other. Allow the fins to dry COMPLETELY in a horizontal position before putting any weight on them. When this layer of glue has dried, apply a second layer of glue to the fin-body joints, forming a fillet with a finger. Let this dry completely, again in a horizontal position. 13. Glue one of the launch lugs to the sustainer on the line marked earlier, with the bottom of the lug even with the bottom 5" mark. The lug should run lengthwise toward the front of the tube. Glue the other lug on the same lengthwise line with the top of the lug aligned to the upper 5" mark. It should also run lengthwise toward the top of the sustainer. Let these dry completely. 14. Assemble the parachute, and attach the shroud lines to a swivel. 15. Attach the shock chord to the inside of the sustainer tube using a folded-paper chord mount, at a depth of 2" down from the top of the tube. Attach the other end of the chord to a swivel. 16. Fill the grain of the fins and the nose cone with a sanding sealer, or other filler, then sand the surfaces smooth with progressively finer grits. 17. Lightly sand the body tubes before applying a primer to allow for better adhesion. Spray at least two coats of primer before sanding, and apply as many coats of primer thereafter as needed to completely seal the surfaces, sanding lightly as needed between coats. 18. The suggested paint scheme is an all-white body, with red, or black, trim colors. No decals are available for this model, however artwork may become available soon to make custom waterslide decals. 19. Attach the swivels to the screw eye at the bottom of the payload section. Flame resistant wadding must be put into the sustainer before packing the parachute for a launch. 20. Slip the sections together, place the rocket on the pad, or a rocket stand, step back, and admire your work!