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One thing I've done is actually use a 3D pen to weld pieces together. The joints are a little ugly but really strong, and you don't need any special glues beyond the filament you already have. It also is great for joining parts with gaps between them, because the pen can easily just spooge...

Thank you for your answers, I guess I overlooked the obvious truth: it doesn't look like it has 29/40-120 closures, it does have them. I am going to contact the rocketeer who sold me these and see if he has a correct set. If he doesn't, I will buy one.

I recently bought a used 29/240 casing that was manufactured (if I am reading the date code right, it is pretty worn) in 1990. Its closures are of a different style than what I see in pictures of newer 29mm high power cases - they look like the closures from my 29/40-120 case. I was wondering if...

The Airfoil Assistants are what I was thinking of. I wonder if there is a free 3D-printable model out there for something like that.

I actually just saw a new product on Apogee, not what you are describing, but your idea reminded me of it. They are 3d printed angle jigs you put sandpaper in to sand a bevel into your fin.

I would personally agree with the recommendation to use an Estes rocket. The motors have a built in pyrotechnic charge to pop the parachute out, which could easily be used to eject some colored powder for the gender reveal. Much simpler and more reliable than relying on gravity to *maybe* pull...

I am doing curved internal rotors because this rocket is designed to fly on anything up to a 29/40-120 G reload. I would worry about aerodynamic stresses on the balsa helicopter blades if they were external. I am not plying or glassing; at this point, my plan is to do 3 layers of 1/16" balsa...

Door skins sound interesting. Where would I find them, a hardware store?

So the plywood blades are a lost cause? Then I will visit the hobby shop for some balsa.

I like the idea of a hardwood spar. I will also likely taper the leading and trailing edges, simply to cut down on drag. I am currently continuing to soak my plywood blades in ammonia, just to see what happens, but if nothing comes of that in the next couple days (which based on your comments is...

The shape I am after is something akin to that described in Peak of Flight #342 (https://www.apogeerockets.com/education/downloads/Newsletter342.pdf). The bend around a mandrel creates the blade's airfoil. I say 1/4" balsa because on BABAR's Whopper Flopper Chopper, which flew on Estes E...

Thank you, mcderek, for that link. It seems that, per the article you linked, I could shape 1/4 inch balsa using the method described there. Do you believe that would be strong enough to withstand landing (hitting the ground while spinning) if I papered it, or would I have to go with a multi...

Thank you for your advice. My worry is about rotor strength when they hit the ground. Your balsa plywood idea seems like it would work and be strong enough; however, making 4 blades with 4 layers each seems like it would be tedious. Do you think a single piece of papered 1/4" balsa would bend if...

I am working on building a MPR (E-G) helicopter rocket, based around an LOC thick wall BT-80, with rotors made of 1/8" model airplane lite-ply. I am attempting to bend the rotors like those in Apogee's Gyro Chaser kit, by soaking them in cleaning ammonia from Home Depot to soften them and then...

This sounds like a good method; super glue would hold better than clamps, while the tape would make it easy to remove.

They have a single cutting edge. However, they appear to be thinner and have more teeth per inch than the other "fine" blades in the pack.

That makes sense based on their appearance; that's probably what I'll use for my rotor blades. Question: Would stacking pieces of wood and cutting the stack work for getting uniform fins and rotors, or is there some problem here I'm not seeing?

Not scroll saw blades, scroll cutting blades for a jig saw. I am not entirely sure what that means, and was hoping someone could shed some light on it.

Thank you. Part of the reason I am doing this is to improve my craftsmanship and hand tool skills, as access to a free makerspace with laser cutter, CNC, etc. has led me to take the easy way often, and as a result my hand tool skills are limited. Another question: I ordered a pack of fine tooth...

I am building a mid-power helicopter rocket, designed around an LOC 2.56-inch tube. It will fly on composite E thru G motors. I am making the fins, CRs and helicopter blades from 3/32 birch plywood. I was going to laser cut the parts using my school's laser cutter or the laser cutter at my local...