OK, an actual update! Yesterday I bit the bullet and put the fins in. Used 5 minute "gel" epoxy, which is thicker than the other stuff, which seemed to work well for double-dipping. What I learned:
-Using a fin template glued to a board is awesome.
-Double-dipping is easy. You'll need more epoxy than you think.
-Wooden coffee stirrers are perfect for stirring epoxy, applying it, and scraping down the joints where the external fillets will go.
-I really should have bought 15 minute epoxy.
Other more mundane stuff: I decided against all the advice I've been given to attach the nose cone permanently. It was a loose fit in the BT and I like the look of an NC that's smoothed into a BT (as opposed to something with and obvious join point). Also I knew that if I punched holes in the rocket, I'd stress about getting everything perfectly lined up, then it wouldn't, and I'd be frustrated. So in it went!
At this point the only thing between me and flight is putting on some fillets and attaching the parachute and acquiring an engine. Oh, and a nomex blanket. Paint will happen; I'd like it to happen before it launches but it's not a necessity.
The template, ready to go:
Everything all laid out... I actually went through the fin assembly once with no glue, pantomiming the gluing, just to see how I'd do in terms of curing time for the glue. Overkill? Maybe, but it helped settle my nerves.
Mixing the glue....
Done! The business end.... (I glued on the motor retainer)
looking flight-ready....