Estes Rockets Starlight 9992 build log

[JoeFilgas]

Just started to build the new Estes Starlight model rocket! Starting off with the engine mount I departed from the directions as I’m installing an 18mm Estes motor retainer thus doing away with the metal hook, split green ring and plastic ring. I sanded the inside of the retainer portion that will receive the epoxy and cleaned with alcohol. I also sanded the bottom 1/4” of the MMT removing the glassine. I placed the threaded portion of the retainer dry on the MMT and drew a reference line in pencil at its terminus to give me the epoxy line. Next I mixed up some high heat JB Weld 2 part epoxy and spread glue on the tube (not the retainer piece) where I had previously marked in pencil. The retainer portion was then placed over the epoxied tube and rotated to seat. The aft inside end was checked for any epoxy, but it was all clear. The excess epoxy around the top of the retainer was wiped off with a paper towel. Next, using wood glue, one of the green centering rings was glued against the retainer on the MMT. I used an extra, un-cut green centering ring I had stored to replace the kit provided split green centering ring. A piece of kevlar shock cord was then tied around the MMT (another kit instruction departure). The last green centering ring was then notched to allow passage of the shock cord and glued in place on the MMT. I went ahead and installed the engine block into the front of the MMT with wood glue and set aside to dry. The fins were next. Using a straight edge ruler, wood glue and T Pins the fin pieces were aligned, glued together, pinned down and left to dry. I did need to sand the small edge of the long pieces before gluing to get a flat mating surface. This is the first kit where all the balsa wood fin pieces came all cut out. Finally I wrapped up the only other thing I could do tonight and that was to install and glue in the eye screw and washer into the Balsa nosecone. This is also the first kit for me with a balsa nose cone.

 

[JoeFilgas]

Tonight’s pics part 2 P.S. I also marked the BT with all the appropriate fin lines.

 

[JoeFilgas]

My Estes Starlight build log: today I added a glue fillet to the motor mount and then released the fins from their pins. The fins were then sanded with the leading edge rounded off. These are very fragile 1/8” soft balsa fins and even thinner for the secondary fins so I decided to fiberglass them all with light 3/4oz cloth and thin CA glue. All glass was applied then all were sanded down and prepped for primer. Finally I shot them all with filler primer and set aside to dry.

 

[JoeFilgas]

Final shots from today’s work.

 

[JoeFilgas]

All the Estes Starlight fins have been wet sanded with 400 grit sandpaper tonight, wiped clean and dried. Since I wet sanded and this is thin balsa I didn’t want to take the chance of these warping at all so all were sandwiched flat with weight just to be safe. Tomorrow I’ll get another coat of primer on, sand and then permanently install on the tube.

 

[JoeFilgas]

My Estes Starlight build: You know me I had to make another slight change in my rockets final look. I used heavy construction paper to create a 3/8” wide band with evenly spaced marks on the centerline. This will give a metal band look to both rings when complete. I used thin CA to secure the strips to the rings. Then on the marks I began laying glue dots to simulate rivets. Next I saturated the balsa nosecone with thin CA, sanded and primered. Then it was onto the second round of primer for all the fins.

 

[JoeFilgas]

To wind up the Estes Starlight build for the night I finish sanded all the fins and re-sanded the root of all fins back down to wood. The modified rivet rings are complete as well. The fins are now ready to be permanently glued to the BT.

 

[JoeFilgas]

My Estes Starlight build log: today all the fins were glued in place. I also primered the rings and the screw on retainer. Going to let this dry awhile and then I’ll fillet glue all the fins.

 

[JoeFilgas]

Glue fillets on all the fins are done and drying!

 

[JoeFilgas]

Here’s a shot with the rings mostly in place and to end the build night off I used some glazing putty to fill the spirals in the BT and rings.

 

[JoeFilgas]

My Estes Starlight rocket build log: today I sanded down the areas I filled with glazing putty last night. Since there is so little space between the fins I had to make a sanding implement from a coffee stir stick and a strip of sand paper. I sprayed the back of the sandpaper and one side of the stick with Elmer’s spray adhesive, waited a minute or so then bonded the sand paper to the stick. As these sticks are not very strong to begin with they only last a little while before another is needed. I kept re-using the sand paper strip. Anyway this allowed me to do some intricate sanding. I also used a larger piece of 220 sand paper for the fin sides. Next all the parts were primered (again). I had to take a “Pretty in Primer” shot with it all together. Finally I glued in the motor mount with wood glue and a stick marked at 2” for the front glue line. It’s all been set aside to dry. I did push the mount in just a tad (1/32”) so I could get a glue fillet there when the mount is dry.

 

[JoeFilgas]

A little more got done on the Estes Starlight tonight. I got the glue fillet installed on the bottom of the motor mount and let dry. Next the entire rocket got wet sanded with 400 grit except for the rings. A few minor imperfections on the main tube/fins were then filled with spot glazing putty. Finally the rings (I didn’t sand these because I want them to have a rougher, textured surface when painted.) were fitted with the internal glue joint/launch lug markings. I’m going to tape off these areas when I paint the inside of the rings. The tape will reveal a clean glue joint as they will be installed after the rocket has been painted. After the final round of primer I’ll expose the wood on the four smaller fins where the rings will eventually be glued to and then tape that off for the color coat. There was a small spiral on the inside of each ring that I filled with glazing putty. One other slight modification I’m making is moving the top ring aft about 1/2” because it’s too big around to fit in the location the directions call for. I’m not worried about any slight CG change as it weighs next to nothing.

 

[JoeFilgas]

My Estes Starlight build log: well not much to report today. I sanded down all the glazing I did last night and prepped the BT for its final primer round. I also masked the glue areas on the inside of both rings and readied for primer. Unfortunately we’re getting showers so that’s all she wrote for today!

 

[JoeFilgas]

My Estes Starlight rocket build log: well the weather wasn’t color paint suitable, but we ain’t to color yet so the final primer coat was added then wet sanded about two hours later. I then removed the primer from the glue areas for the rings and will mask that for the color coat. I’ll paint all the parts separately and then glue on the rings followed by the launch lugs. The lugs will require some brushed on touch up paint. So it’s now all ready for color when the weather allows!

 

[JoeFilgas]

My Estes Starlight rocket build log: was able to get the gloss grape on the main body/fins. I then shot metallic silver on the nosecone, rings and motor retainer. Once those dried I shot some Tamaya Color (purple) for polycarbonate over the silver. You can’t tell really well under indoor light the contrast these will have with the main body. Out in the sun those parts really sparkle and pop! Getting there!

 

[JoeFilgas]

Had to slap all the parts of the Starlight together to see how it’s going! I can say the indoor lighting does nothing for the metallic which explodes in the sunlight! Now onto Lorrena for some vinyl graphics!

 

[JoeFilgas]

My Estes Starlight rocket build log: today I epoxied the rings on as well as the launch lugs. Did a small amount of touch up paintwork like painting the launch lugs. My Bride Lorrena, once again hit it out of the park with the vinyl decals all of which were applied. All that’s left is to obtain a barrel swivel and connect the parachute, which also just happens to be purple and white! Tomorrow is the official debut video and still pictures of the build.

 

[JoeFilgas]

Presenting “Purple Rain”! Still need to connect the laundry. I’ll post a YouTube link to a short video, but it may get taken down by YouTube.

 

[JoeFilgas]

 

[JoeFilgas]

The final details to complete “Purple Rain” were done this afternoon which entailed attaching the Kevlar shock cord to the nosecone, parachute which I love the fact it came purple and the barrel swivel. It’s is now in a ready to fly status. That was a really fast and fun build at 10 days.

 

[billeblurzz]

Love the video and the rocket! Very cool!!! That song brings back memories! The summer it came out I was trying to get into boat racing…I was on the way to Nat. Championships in an obscure place in Brigeport Texas. All day to get there and that song was on radio all day. Got there after midnight and all rooms were taken…out in nowhere west Texas! This was before I discovered Rocketry as my hobby! Much safer and loved it for 30+ years!

 

[JoeFilgas]

Love the video and the rocket! Very cool!!! That song brings back memories! The summer it came out I was trying to get into boat racing…I was on the way to Nat. Championships in an obscure place in Brigeport Texas. All day to get there and that song was on radio all day. Got there after midnight and all rooms were taken…out in nowhere west Texas! This was before I discovered Rocketry as my hobby! Much safer and loved it for 30+ years!

Thanks so much! Isn’t great how an old song can transport you back to past memories?