Estes Nasa Pegasus 2.5" Upscale build.

Back_at_it

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It's been a while since I started a new project as I took little bit of a break during the cold crappy winter we had but with the weather turning it's time to build again. This time I'm going to upscale my favorite rocket. This is something I've been planning for a while and I've had the tubes cut and sitting on the bench since Dec.

I'm building a 2.5" upscale of the Nasa Pegasus using Estes PSII tubes and nosecone for the main tube. Doing the math this comes out to be a 188% upscale. I'll list the materials used below if anyone if is looking to duplicate my build.

Nose Cone. Estes PSII 2.5" #072413
Lower Body tube. Estes 2.5" Dia. tube 15.5" long. # 031390
Upper Body Tube. Estes 2.5" Dia. tube 10.25" long #031390
Estes Coupler. 2.5". #030189
Side tubes. Centuri #18. 12.5" long.
Motor Tube. BMS 2mm motor tube. 12" long.
Centering rings are 1/16" thick Plywood.
Baffle plates are 1/16" thick Plywood.
Fins are 3/32" Plywood.
Motor retainer. Estes 29mm #009750

Several months back I cut all of the tubes and baffle plates and they have been sitting on the bench waiting for me to come back to the hobby. Below are the materials used minus the fins.

1.jpg

With the fins on this one I decided to do things a little differently. Due to their size I decided to fill and seal them on the bench before attaching. Here we see the fins after one coat of wood filler and two coats of Minwax sanding sealer. They still need a final wet sanding to make the sanding sealer dead flat but they are getting close.


14.jpg

With the fins drying I turned my attention to the motor mount. For this build I'm going with a 29mm mount. The motor/stuffer tube is 12" long. A motor block was placed 4.25" up inside inside the tube to allow this to fly on Estes E and F motors as well as the composites.

To begin the assembly the outer layer of the motor tube was removed where the centering rings attach. The centering rings have been sanded and fit specific to the top and bottom of the tube so they have been marked accordingly.

3.jpg

Centering rings were attached using TBII. Two fillets were applied. The first fillet was done with TBII for penetration. The second was done with Thick and Quick.

5.jpg

Since I had good access I went ahead and installed the Estes 29mm motor retainer using BSI 30 min. epoxy.

4.jpg

That is as far as I've got on this one. Hope to sneak down stairs between calls to get the baffle built between meetings today.

Thanks for following along.
 
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Back_at_it

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Sorry for the delay. I've made good progress on this project. I was hoping that it would have been ready for a test flight for my outing yesterday but unfortunately I was not able to get it far enough along to fly.

Assembled the baffle. The baffle is made from 1/16" ply cut into half moon shapes. The baffles overlap each other by approx. 1/4". The upper plate has a couple of scrap pieces of plywood to reinforce the area where the screw eye attaches.

6.jpg 7.jpg

While the baffle was drying I inserted the motor tube into the lower body tube. The motor tube was inserted until the end of the motor retainer was even with the rear of the tube. The 2.5" body tube allows tons of room to attach the screw on portion of the motor retainer.


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With the baffle dry I lightly sanded the outside of the coupler tube for better penetration. TBII was then used inside the tube and on the outside of the coupler. Have a wet rag near to wipe off the excess glue.


9.jpg

I then added a length of 700# Kevlar to the eye hook as a leader for the shock cord.

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It is now time to add the side tubes. The side tube sit even with the bottom of the main tube. The attachment points were sanded lightly for better bond and attached with TBII. A single glue fillet was then applied and let dry over night.

12.jpg

After the glue dried there were some open voids in the glue that needed to be addressed. These were filled in with DAP wood filler and let dry for an hour. Rough sanding was completed but there is more finish sanding left to go.

16.jpg
 
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Back_at_it

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Now it's time to make this thing look like the Pegasus.

The first wing was installed. The wings attach 3.29" from the rear of the main body tube. To get the angle correct I used 1/4" launch lugs as spacers. These work perfect and the wings are at the exact same angle when measured against my original Nasa Pegasus.

The body tube outer layer was removed where the wings attach to the main tube and outer tube. In the pic below we see the first main wing already installed with the second fin ready to go on.

17.jpg

Second wing is attached and drying.

19.jpg

Next was the upper vertical wings. When I added the wood filler earlier I forgot to leave space for the tails so I had to break out the dremal and remove the wood filler where the upper wings attach. They were then glued in place with TBII and allowed to completely dry before going any further.

This is the current state of the project. I'm going to do the fillets before adding the upper tube so the next couple of day will be watching glue dry.


20.jpg 21.jpg 22.jpg
 
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Huxter

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Sweet build! Thanks for including parts and instructions. I'm a big Star Trek fan and have built plastic models before. Now I can create a flying Pegasus! Love the 700# Kevlar - big Tim Allen Grunt!
 

Back_at_it

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Managed to get the fillets completed yesterday so it's time to attach the upper tube. Applied a generous coating of TBII to the inside of the tube and the outside of the coupler and slide them together.

23.jpg 25.jpg

Wanted to ensure that I had a good fillet around the top of the upper plate of the baffle so I went a little heavy on the glue around the top of the tube. Worked out perfect Now it's just a matter of letting this dry.

27.jpg

Tomorrow will be launch lugs and the recovery gear. If I play my cards right I might be able to get this one out for a stability flight this weekend before painting it.
 

Charles_McG

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Looking good! I got my L2 with a 4" upscale based on a mega der rex max kit, leviathan tubes and some custom laser cut plywood.
 

Back_at_it

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Looking good! I got my L2 with a 4" upscale based on a mega der rex max kit, leviathan tubes and some custom laser cut plywood.
I do have a bunch of those 4" Max nose cones. As of right now I only have three of the nose cones allocated to future builds so I have a couple that could be used. Might just need to follow your lead.
 
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Back_at_it

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Got up early this morning as I really wanted to get this one wrapped up. Hoping to fly it this weekend and wanted to give everything a good couple of days to cure before launch.

Added the launch lugs. Used 1/4" lugs from ERockets. Cut the lower lug at 2.5" and the upper and 2.0". The edges were then angled for aesthetics. I used an old launch rod to get them aligned. Tacked in placed with instant cure then applied TBII. Will go back with TBII for the fillets.

28.jpg

Forgot to get a pic of the recovery. Added 8' of 1/2" elastic for the shock cord. One end was attached to the Kevlar leader and the other was looped through holes drilled in the base of the nose cone.

Here are some pics with the nose cone attached. Mechanically it's ready to fly. Just going to give everything a couple days to cure before launching. Will do the finishing after it has flown. If there are going to be any issues I'd like to find them before finishing.


29.jpg 30.jpg
 

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Hope everyone enjoyed their holiday weekend. I managed to get out and fly at Bong this weekend but only had time for a few flights but that was ok as my main reason for going was to get the Pegasus 2.5" up for it's stability flight before finishing.

After adjusting the final weights and running the SIM in OR I decided to go with an E30-4 for the first flight. SIM'ed 38.2mph off the rod with low max G of 8.55 and max velocity of 134mph so I figured this was a nice low stress motor with a lot of thrust to get it off the pad. Apogee projected at 508ft.

Actual apogee of 489ft but it left the pad strong. Only very minor weather cocking but the winds we between 5 and 10 mph so not bad. Landed about 200ft from the pad on a 30" Nylon chute.

Now it's time for primer, paint and vinyl. PEGASUS 2.5 UPSCALE 1 FIRST STABILITY FLIGHT 05232022.jpg PEGASUS 2.5 UPSCALE 3 FIRST STABILITY FLIGHT 05232022.jpg PEGASUS 2.5 UPSCALE 4 FIRST STABILITY FLIGHT.png PEGASUS 2.5 UPSCALE 5 FIRST STABILITY FLIGHT.png PEGASUS 2.5 UPSCALE 6 FIRST STABILITY FLIGHT.png
View attachment Pegasus Stability flight.MOV
 

brockrwood

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It's been a while since I started a new project as I took little bit of a break during the cold crappy winter we had but with the weather turning it's time to build again. This time I'm going to upscale my favorite rocket. This is something I've been planning for a while and I've had the tubes cut and sitting on the bench since Dec.

I'm building a 2.5" upscale of the Nasa Pegasus using Estes PSII tubes and nosecone for the main tube. Doing the math this comes out to be a 188% upscale. I'll list the materials used below if anyone if is looking to duplicate my build.

Nose Cone. Estes PSII 2.5" #072413
Lower Body tube. Estes 2.5" Dia. tube 15.5" long. # 031390
Upper Body Tube. Estes 2.5" Dia. tube 10.25" long #031390
Estes Coupler. 2.5". #030189
Side tubes. Centuri #18. 12.5" long.
Motor Tube. BMS 2mm motor tube. 12" long.
Centering rings are 1/16" thick Plywood.
Baffle plates are 1/16" thick Plywood.
Fins are 3/32" Plywood.
Motor retainer. Estes 29mm #009750

Several months back I cut all of the tubes and baffle plates and they have been sitting on the bench waiting for me to come back to the hobby. Below are the materials used minus the fins.

View attachment 519294

With the fins on this one I decided to do things a little differently. Due to their size I decided to fill and seal them on the bench before attaching. Here we see the fins after one coat of wood filler and two coats of Minwax sanding sealer. They still need a final wet sanding to make the sanding sealer dead flat but they are getting close.


View attachment 519297

With the fins drying I turned my attention to the motor mount. For this build I'm going with a 29mm mount. The motor/stuffer tube is 12" long. A motor block was placed 4.25" up inside inside the tube to allow this to fly on Estes E and F motors as well as the composites.

To begin the assembly the outer layer of the motor tube was removed where the centering rings attach. The centering rings have been sanded and fit specific to the top and bottom of the tube so they have been marked accordingly.

View attachment 519300

Centering rings were attached using TBII. Two fillets were applied. The first fillet was done with TBII for penetration. The second was done with Thick and Quick.

View attachment 519301

Since I had good access I went ahead and installed the Estes 29mm motor retainer using BSI 30 min. epoxy.

View attachment 519302

That is as far as I've got on this one. Hope to sneak down stairs between calls to get the baffle built between meetings today.

Thanks for following along.

Managed to get the fillets completed yesterday so it's time to attach the upper tube. Applied a generous coating of TBII to the inside of the tube and the outside of the coupler and slide them together.

View attachment 520207 View attachment 520208

Wanted to ensure that I had a good fillet around the top of the upper plate of the baffle so I went a little heavy on the glue around the top of the tube. Worked out perfect Now it's just a matter of letting this dry.

View attachment 520210

Tomorrow will be launch lugs and the recovery gear. If I play my cards right I might be able to get this one out for a stability flight this weekend
before painting it.

I covet your workshop. Nice!
 

Back_at_it

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Guys this one kind of got pushed to the side and honestly I have been so busy working on other stuff that I forgot about it. Since the last update I got all of the filling and sanding done along with one last coat of white primer before shooting on four coats of Krylon Gloss White. Even the insides of the tubes were sealed and painted.

Hoping to get to work on the vinyl on this one later this week.



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