Just a comment on making the tubes smooth. He uses autobody filler. When building our Delta II project we made a 'rotisserie'. It was big enough to hold two boosters (3" x 36" long) We had them on the spindle and then we added West Systems fairing compound to epoxy and painted it on. Then we started them spinning at 11 RPM. In 2 hours we had a *perfect* tube. Nice and smooth with a glass like finish. We took some 600 to it so paint would stick and we were done.
Which would work better for this application, fg matting or fg cloth? If cloth, would 6 oz layer work with a final coat of something like 2 oz to be smooth? If matting, would the stuff you get at walmart or home depot work and have a final layer of 2oz for it to be smooth? Thanks!