Go to
www.nasaspaceflight.com and check out the forums section. There is a LOT of data over there about Ares I and TONS of links. Sorry I'm away from my regular computer so don't have direct access to my links or I'd share. There is a good one that you can find by googling Ares I though, can't recall the name right offhand but it has a lot of good information about it. There is also some good paper models out there that possibly have files you could peruse for scale data.
Ares I has changed more than times than a crack dealer's underwear at a policeman's convention. The outer mold line of the design has changed repeatedly in response to the severe problems they've been having with the design and trying to squeeze every possible ounce of weight and performance out of the design. The latest (IIRC) is the 606 Orion and the "Kaiser hat" boost protective structure, which actually enshrouds the conical Orion capsule inside an ogive boost protection cover for improved aerodynamics and reduced drag. There has also been some development work on the MLAS escape system which would replace the tower and tractor escape rocket with 6 solid rockets mounted circumferentially around the BPS, but I understand that while it's still in the mix for future upgrades or Lunar Orions it's not baselined for the ISS Orions. It's all pretty confusing and you really have to hunt for the information, as it's not as 'open' as you'd expect.
I turned a really nice balsa nosecone for a BT-70 upper stage for a 1/100 Ares I (D/E power) in the 606 version (pre-bullet BPS) and I'm sticking with it.
Good luck! OL JR
