luke strawwalker
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Well, one good build thread deserves another, so I'm going to detail my recent construction of the Dr. Zooch Saturn V while on holiday in Indiana.
The kit is based on a BT-60 main body tube with a BT-50 S-IVB above the transition. The kit consists of these two tubes, an engine tube, various motor mount parts, centering rings, a second BT-20 tube which becomes the conical section Saturn V engine fairings, a couple wrap sheets for the body tubes and F-1 engines, service module, capsule, tower, LES motor nozzle fairing, a wooden LES rocket on top of the capsule (which appears to be a surgically altered golf tee), balsa nosecone, balsa transition, sheet balsa for fins, and surprisingly, a decal sheet. The ubiquitous Dr. Zooch comic instructions are a given...
So, lets get started. First off was construction of the motor mount. This rocket is powered by a single 18 mm motor in stock form, and that's what I went with for the build. It's a typical motor mount in all respects. The motor mount consists of engine tube, engine hook, reinforcing band to prevent hook ripouts of the tube, centering rings, and an engine block ring. Somehow I managed to forget to glue in the motor block ring until after I installed the completed motor mount inside the longish BT-60 main body tube, so I had to surgically install it using a very specialized highly sophisticated installation tool (OK, so it was a magic marker taped to a foot long marking aluminum angle with the ring slipped on the end, but it was kinda ingenious and got the job done!) Once installed the motor mount and body tube is set aside to dry.
The nosecone occupied my next attention. It's rather unusual in that it's flat on top. You pull it out of the box and you're faced with something that looks like the S-IVB spacecraft adapter section that housed the LM, which is a long tapering adapter topped by a cylindrical section like the Apollo Service Module, with a flat, chopped off top with a small 1/4 inch by about 1/16 inch deep dimple drilled in the end. A wrap simulates the cylindrical SM at the top of the nosecone, but the lower half is painted white to look like the Spacecraft Adapter. So, this half of the nosecone needs to be filled and sanded. First you have to make sure that there is a distinct line sanded in the nosecone where the cylindrical SM section starts to taper as the LM Adapter-- it tends to be a bit rounded from the factory but a couple passes with 220 grit or a small sanding file will quickly make a sharp transition between the two. I carefully measured the SM wrap and then marked the nosecone all the way around where the sanding line needed to be, then worked my way around with a sanding board a few times sanding up to the line to make the sharp transition. Next, I hardening the nosecone with thin CA glue. A quick sanding with 220 grit takes off any hardened fuzz and sawdust/CA rough crud. Next I brushed on a layer of thinned Elmer's Wood Filler to cover the grain and smooth the nosecone out, and when dry sanded most of it off with 220 grit paper. Next came two heavy coats of gray W/M Colorplace 98 cent primer, another sanding with 220 grit, and then a followup with 600 grit wet/dry paper using a bit of water to prevent the paper from clogging and remove the sanding mud. With an hour of work the nosecone now looked like plastic and was ready for paint. The entire rocket is 'mocked up' at this time (stacked using the transition, body tubes, and nose cone) and painted W/M Colorplace Flat White enamel. The transition requires no surface prep, as it's covered with a paper wrap to simulate the look of the stringers on the tapering S-II/S-IVB stage adapter transition complete with roll patterns and retrorockets. This is cut from the wrap sheet and carefully glued together, clamped with a smooth-jawed hemostat and set aside to dry for later installation over the balsa transition. At the same time, the F-1 engine bells are cut out of the wrap sheet and glued up with white glue. Each F-1 engine consists of an upper and lower engine bell half, so there are ten to do. Set them aside to dry.
Here's a few pics-- more to come... OL JR

The kit is based on a BT-60 main body tube with a BT-50 S-IVB above the transition. The kit consists of these two tubes, an engine tube, various motor mount parts, centering rings, a second BT-20 tube which becomes the conical section Saturn V engine fairings, a couple wrap sheets for the body tubes and F-1 engines, service module, capsule, tower, LES motor nozzle fairing, a wooden LES rocket on top of the capsule (which appears to be a surgically altered golf tee), balsa nosecone, balsa transition, sheet balsa for fins, and surprisingly, a decal sheet. The ubiquitous Dr. Zooch comic instructions are a given...
So, lets get started. First off was construction of the motor mount. This rocket is powered by a single 18 mm motor in stock form, and that's what I went with for the build. It's a typical motor mount in all respects. The motor mount consists of engine tube, engine hook, reinforcing band to prevent hook ripouts of the tube, centering rings, and an engine block ring. Somehow I managed to forget to glue in the motor block ring until after I installed the completed motor mount inside the longish BT-60 main body tube, so I had to surgically install it using a very specialized highly sophisticated installation tool (OK, so it was a magic marker taped to a foot long marking aluminum angle with the ring slipped on the end, but it was kinda ingenious and got the job done!) Once installed the motor mount and body tube is set aside to dry.
The nosecone occupied my next attention. It's rather unusual in that it's flat on top. You pull it out of the box and you're faced with something that looks like the S-IVB spacecraft adapter section that housed the LM, which is a long tapering adapter topped by a cylindrical section like the Apollo Service Module, with a flat, chopped off top with a small 1/4 inch by about 1/16 inch deep dimple drilled in the end. A wrap simulates the cylindrical SM at the top of the nosecone, but the lower half is painted white to look like the Spacecraft Adapter. So, this half of the nosecone needs to be filled and sanded. First you have to make sure that there is a distinct line sanded in the nosecone where the cylindrical SM section starts to taper as the LM Adapter-- it tends to be a bit rounded from the factory but a couple passes with 220 grit or a small sanding file will quickly make a sharp transition between the two. I carefully measured the SM wrap and then marked the nosecone all the way around where the sanding line needed to be, then worked my way around with a sanding board a few times sanding up to the line to make the sharp transition. Next, I hardening the nosecone with thin CA glue. A quick sanding with 220 grit takes off any hardened fuzz and sawdust/CA rough crud. Next I brushed on a layer of thinned Elmer's Wood Filler to cover the grain and smooth the nosecone out, and when dry sanded most of it off with 220 grit paper. Next came two heavy coats of gray W/M Colorplace 98 cent primer, another sanding with 220 grit, and then a followup with 600 grit wet/dry paper using a bit of water to prevent the paper from clogging and remove the sanding mud. With an hour of work the nosecone now looked like plastic and was ready for paint. The entire rocket is 'mocked up' at this time (stacked using the transition, body tubes, and nose cone) and painted W/M Colorplace Flat White enamel. The transition requires no surface prep, as it's covered with a paper wrap to simulate the look of the stringers on the tapering S-II/S-IVB stage adapter transition complete with roll patterns and retrorockets. This is cut from the wrap sheet and carefully glued together, clamped with a smooth-jawed hemostat and set aside to dry for later installation over the balsa transition. At the same time, the F-1 engine bells are cut out of the wrap sheet and glued up with white glue. Each F-1 engine consists of an upper and lower engine bell half, so there are ten to do. Set them aside to dry.
Here's a few pics-- more to come... OL JR




