My L3 build - Performance Rocketry Competitor 6

[SynergyAero]

I'm finally starting my Level 3 build!!

Originally I wanted to scratch-build my Level 3 project. However, as I live in an upstairs condo with no garage, I figured it would be more practical to start with a kit and modify it to suit my needs. After asking around on the forums, I decided to purchase a Competitor 6 by Performance Rocketry.

I ordered the kit online from Liberty Launch Systems, and received it just a few days later.

While waiting for the kit to arrive, I downloaded the rocksim file from LLS' website. Once I looked at the rocksim file, I realized there were a few places I could improve the kit:

- Convert the kit to a "zipperless" design
- Alter the airframe sections to allow for longer motors
- Adjust the payload bay sizes to better fit my recovery equipment
- Move the avionics bay farther foward for better CG to CP relationship
- Add a 4th birch MMT centering ring (for easier installation of 98mm aero-pack retainer)

Hardware & electronics:

- Rouse-Tech 24g CD-3 system (main deployment)
- Rouse-Tech 16g CD-3 system (drogue deployment)
- Dual Perfectflite MiniAlt/WD altimeters
- Rocket Rage drogue (28") chute
- Rocket Rage RRQS100 main chute
- Public Missiles 0.75" tubular nylon
- Public Missiles linear rail lugs (for 1515 series rail)
- Keystone aluminum battery holders
- Aero-Pack RA98 motor retainer
- MissileWorks rotary switches for arming avionics systems

Below are the drawings and diagrams that I prepared for my TAP's. These detail the kit modifications, avionics bay design, electronics shematics, recovery system, and modifications to my existing launch pad.

I am now beginning construction, and I will post pictures of the build process as I go...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6antizipper.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6antizipper.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6boostersection.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6boostersection.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6payloadbays.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6payloadbays.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6nosecone.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6nosecone.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6avionicsbay.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6avionicsbay.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6avionicsbayendview.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6avionicsbayendview.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6avionicsschematic.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6avionicsschematic.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6recovery.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6recovery.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6cgandcp.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6cgandcp.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6onpad.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6onpad.jpg" border="0" alt="Photobucket"></a>

 

[Snoman]

Chris

Very Nice

I'd check your booster length!!!!!!! " Diamensions"

The 98/15360 is ( 41.698 ) inches long ( N-2000W ) Aerotech !!!!!!!!!!!!

Your CAD drawings says your booster length is 38 inches!!!!!!!!!!!!!!!!



Chris I'm dusting off all that 80/20 goodies I picked up back in May or June

of last year and get started on the launch pad on Sunday.

What size allen head bolts did ya use ??????????? length also.

Hey keep us updated on your Level 3 build

looks like it out to haul Mass!!!!!

Keep in touch

Snoman

 

[SynergyAero]

The kit contents...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=02kitcontents.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/02kitcontents.jpg" border="0" alt="Photobucket"></a>

Drilling out the motor mount centering rings to accomodate 5/16" all-thread...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=04drillingcenteringringholes.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/04drillingcenteringringholes.jpg" border="0" alt="Photobucket"></a>

Notching the G10 fins to clear the middle centering ring...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=05cuttingcrslotinfins.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/05cuttingcrslotinfins.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=06crslotinfinscut.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/06crslotinfinscut.jpg" border="0" alt="Photobucket"></a>

Installing the all-thread with stainless steel washers and lock nuts...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=08installingall-thread.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/08installingall-thread.jpg" border="0" alt="Photobucket"></a>

The finished centering ring assembly with all-thread installed...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=09all-threadinstalled.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/09all-threadinstalled.jpg" border="0" alt="Photobucket"></a>

Scuff the motor mount tube where centering rings will attach...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=11sandingmotormounttube.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/12sandingmotormounttube.jpg" border="0" alt="Photobucket"></a>

Motor mount tube with centering rings epoxied in place...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=14centeringringsepoxiedtommt.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/14centeringringsepoxiedtommt.jpg" border="0" alt="Photobucket"></a>

 

[Gym_Class_Hero]

Looks nice so far!

 

[SynergyAero]

Thanks Snoman =)

The booster airframe is 38", but the coupler is hollow inside and extends past the end of the airframe another 6", for a total of 44" of motor clearance!

As far as my cap screws on my launch pad... the ones that go through 1/4" aluminum and then into 1515 rail are 5/8" long I believe. The 1515 rail has enough clearance in its channels for about 3/8" of thread. With the 1/4" aluminum plate being bolted on, that comes to 5/8" total.

Good luck with the pad!

Cris

 

[fox_racing_guy]

Beautiful write up, very professional looking!
Your either single or have a very understanding wife/GF to be cutting that G10 inside.

 

[talkin Monkey]

Outstanding presentation and planning...Really, WOW.

Please post all the pics and addendums you can.

 

[kandsrockets]

Very nice write up. Is this a TRA or NAR L3. If it is a TRA cert. your redundent electronics is not a true redundent system. For my L3 I was told that each system has to be its own (switch, battery, alt, ejection system). 2 matches cannot fire one charge.

 

[Johnnie]

Very well thought out presentation, excellent work. I too question the switches; is 6 really neccessary? From a TRA stance, 1 switch for each altimeter is sufficient. I will be running two on my airframe.

Johnnie

 

[dixontj93060]

Absolutely BEAUTIFUL!

One suggestion though. I always feel better with a pin or two inserted across the breadth of the nosecone to hold the bulkhead assembly in place as epoxy often does not adhere as well to the inside of the nosecone. Since it looks like you are trying to make the bulkhead in the nosecone removeable the pins (old bicycle spokes work well) should be placed on the aft side of the washer at the end of the nosecone and embeded in the epoxy. After the epoxy dries just cut them off with a aw and sand them flush with a file.

In the picture below you can barely see the two cross pins at the top the nosecone on my L2 rocket.

 

[SynergyAero]

Chopped fiber fillet above top centering (will add other fillets once fins are tacked in place)...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=15choppedfiberfilets.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/15choppedfiberfilets.jpg" border="0" alt="Photobucket"></a>

Beautiful write up, very professional looking!
Your either single or have a very understanding wife/GF to be cutting that G10 inside.

She is very understanding, she builds her own rockets in the house too!

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=nikiafterG61flight.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/nikiafterG61flight.jpg" border="0" alt="Photobucket"></a>

Very well thought out presentation, excellent work. I too question the switches; is 6 really neccessary? From a TRA stance, 1 switch for each altimeter is sufficient. I will be running two on my airframe.

I use the 2nd and 3rd switch on each alt. as a safety measure. They shunt the altimeter's main and drogue outputs, to eliminate any chance of the charges accidentally going off while the rocket is being loaded onto the pad. Once it is on the pad, I turn the switches and listen for the beeping to know the charges are "live". Maybe I am wrong here, perhaps just keeping the alt powered off is enough. I will post a message in the recovery section to avoid this thread getting off topic. Here's the new thread

I always feel better with a pin or two inserted across the breadth of the nosecone to hold the bulkhead assembly in place

Good idea =) I will do that... Dont have any bicycles I want to chop the spokes off of, so I'll go get a piece of piano wire form the hobby shop. That stuff is pretty hard.

 

[SynergyAero]

I decided to cut the fin slots all the way down to the bottom of the airframe, so I could build the fincan first, reinforce it, then slide it into the airframe once complete...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=16cuttingfinslots.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/16cuttingfinslots.jpg" border="0" alt="Photobucket"></a>

Smoothing out the rough cuts...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=17filingfinslots.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/17filingfinslots.jpg" border="0" alt="Photobucket"></a>

Sanding the motor mount tube and the fins, to rough up the areas to be epoxied...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=18sandingmmt.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/18sandingmmt.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=19sandingfins.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/19sandingfins.jpg" border="0" alt="Photobucket"></a>

I designed a fin alignment guide on the computer, printed it, and applied it to a flat board to make an alignment jig...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=20finguide.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/20finguide.jpg" border="0" alt="Photobucket"></a>

Using 30 minute epoxy, I tacked the fins in place. While the epoxy was still wet, I slid the assembled fincan into the booster airframe to align the fins correctly. Used a right angle, along with the printed fin guide to make sure all fins were true...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=21aligningfins.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/21aligningfins.jpg" border="0" alt="Photobucket"></a>

Once the epoxy cured completely, I removed the fincan from the airframe. Now it's ready for some reinforcement...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=22finsglued.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/22finsglued.jpg" border="0" alt="Photobucket"></a>

 

[mach66]

I hate you... Just kidding..
One of these days, I am going to build either a completely FG or completely CF rocket.. Well I do have a the Concept 54, which is pretty much that, but I want to do big'un like that.

Very nice on all accounts!!! Should be an awesome project, and seeing where you live, you pretty much have to build like that jsut to keep up With your local crowd.

Brent

 

[SpartaChris]

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=competitor6onpad.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/competitor6onpad.jpg" border="0" alt="Photobucket"></a>

OK, this just cracked me up. Thanks, I needed a new wallpaper..

 

[SynergyAero]

Hehe I thought you might like her!

 

[Art Upton]

Hehe I thought you might like her!

Yea, I Like that CAD drawing

 

[Sailorbill]

Synergy.
A couple of questions on your construction.
1. I see you used allthread to hold the fin can together but it is not tied to the bulkhead that your recovery harness ties to. This means that you are planning on the bulhead and the epoxy to withstand the deployment forces buy themselves. Why not tie the two together for the most strength?

2. On your nose cone I am not sure if the bulkplate is removeable or not but I would think that it is for adding nose weight. Again you seem to be counting on on the bulkplate withstanding the deployment forces. Why not replace the U bolt with an eye nut? This would put all of the stress on the allthread eliminating a failure point.
I have attached a picture of my 6" nosecone for an example.

3 Again dealing with deployment forces. In your Ebay you are again relying on your bulkplates to withstand the force. Why not replace the Ubolts with a single piece of allthread and an eyenut on either end? This again would put the stress on the strongest component the allthread. If strength is a concern you could always go to B7 or B16 rated rod.

This is not ment to be critical. I am in the planning stages of an L3 capable rocket myself and i am trying to make the simplest and strongest rocket possible without over building it.

I wish I had access to a cad program but allas I do not. I love your drawings as they lay every thing out so nicely.

 

[SynergyAero]

Sailorbill,

Thanks for the suggestions. I wasn't planning on making the nosecone bulkplate removable, but I like what you did. I may have to adopt that idea!

What keeps the bulkheads in place is something I have used in my other rockets, and it seems to work rather well. I didn't clarify it my drawings very well, so I changed the color to a bright green.

I dont know of any technical term to describe this, but I call it a "spring-loaded retainer". Here's my best effort to describe it:

I have a scrap of G10 airframe tubing, which I cut into small pieces (approx. 1.5" long). Then I cut a 1/4" to 1/2" section out of those "slices" of airframe. This makes each piece into a "spring-loaded" piece of tubing, which I can compress and place inside the G10 coupler (or nosecone), just in front of the bulkhead(s).

This piece is epoxied in place, and helps retain the bulkheads. Since there is a LOT more surface area being epoxied, it makes the bulkheads that much stronger and secure. Plus on the heavier booster stage, I doubled up the bulkplates - (1) 1/2" birch bulkplate bonded to a G10 fiberglass bulkplate.

Your concern for the strength of the bulkheads got me to thinking, and I decided to make my retainers 1.5" instead of 0.75" as I had originally planned.

I thought about running the entire length with the all-thread, but I really wanted to avoid adding any more weight to the rear of the rocket. I didn't want to use all-thread to begin with, but I figured I better at least strengthen the motor mount / fincan.

I also lengthened the shock cords by 50%, to 45' (originally 30') to help relieve some stress on the connecting components.

Here is a closeup of the retainer design:

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=bulkplatecloseup.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/bulkplatecloseup.jpg" border="0" alt="Photobucket"></a>

 

[Sailorbill]

I see now. I have used this method too I call it a "Coupler within a coupler" and it sure does add to the solidity of the mount.
On the motor mount I have thought about using lengths of tubular Kevlar with loups in each end. One end will be attached to the lowest centering ring with an eye bolt then the TK will be fed through holes in the other rings to an eye bolt in the top bulkplate. This should be lighter and almost as strong as the all thread.

The nose cone has a 3" body tube set in the middle for the weight if needed and I plan on putting a 38 or 29 mm body tube along side for a tracker.

 

[SynergyAero]

Started working on the carbon fiber fin reinforcements today. I went down to US Composites and picked up some 2" wide carbon fiber tape.

First, I laid down a layer of 3:1 thin resin...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3&#37;20build%20-%20Competitor%206/?action=view&current=25spreadingouttheresin.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/25spreadingouttheresin.jpg" border="0" alt="Photobucket"></a>

Then I laid the carbon fiber tape in place, tucking it into all the crevices...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=26applyingcftape.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/26applyingcftape.jpg" border="0" alt="Photobucket"></a>

Then soaked the carbon fiber in more 3:1 thin resin, working the resin in with a disposable brush...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=27brushingresinovercf.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/27brushingresinovercf.jpg" border="0" alt="Photobucket"></a>

A few hours in the Florida sun, and voila! Next, I will add more chopped fiberglass fillets around the centering rings.

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=28cfapplied.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/28cfapplied.jpg" border="0" alt="Photobucket"></a>

 

[SynergyAero]

Yesterday I applied fillets above and below each centering ring, using 1/2" chopped glass mixed with US Composites' 1:1 thick epoxy resin. Thats about it for the fin can! Gotta get the booster airframe cut to length next, so I can install the fin can and add the final fillets...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/?action=view&current=29cfandfilletscomplete.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/L3%20build%20-%20Competitor%206/29cfandfilletscomplete.jpg" border="0" alt="Photobucket"></a>

 

[ghost]

Awesome build!
I love the CAD drawings. What program did you use?

 

[SynergyAero]

Thanks, Ghost. Its a program that I use for work, called Corel Draw. I'd say its more of a graphic design package, than engineering software. But it allows me to draw things very precisely to scale, and I have been using it for about 10 years, so I am very comfortable with it.

 

[ghost]

Cool! Too bad its not freeware

 

[t bone]

Real nice, everything . The cad drawings, the chick, the build and the way you are laying out the thread in general . Thats detail
Terry

 

[BayouRat]

Nice job! Looks good so far. Reminds me of my Competitor 5 build.

https://www.kodakgallery.com/I.jsp?c=5pw5h2x.8u3nijvh&x=0&y=veruz5

Hope you enjoy it as much as I do my Comp.5

 

[SynergyAero]

Thanks guys =) Hey! A competitor 5 build - I gotta go check it out! Havent seen many build threads on the Competitor kits. Thanks for posting the link

Cris

 

[aerospike]

Beautiful drawings, the 69" dimension is a nice touch. The bulkhead in the nose ain't going anywhere although I don't see the purpose (other than positioning the c-rings) for any of the all-thread in the fincan/MMT, or nose.

 

[SynergyAero]

Ok, its been a while since I updated my build thread. Been working on the rocket, but theres been too many birthday parties, anniversaries, meetings, etc to post the photos! So here goes...

I decided to use aluminum as a backplate for the rail guides, instead of plywood. I cut some aluminum pieces to the same size as my rail guides, and scuffed them with sandpaper for better adhesion:

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=30aluminumbackplatescutandsanded.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/30aluminumbackplatescutandsanded.jpg" border="0" alt="Photobucket"></a>

I wanted to double up the aluminum backplates, so I mixed and applied some US Composites 1:1 thick epoxy to bond them together:

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=31backplatesepoxied.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/31backplatesepoxied.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=32backplatesbonded.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/32backplatesbonded.jpg" border="0" alt="Photobucket"></a>

Then marked the holes...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=33markholelocationsinbackplates.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/33markholelocationsinbackplates.jpg" border="0" alt="Photobucket"></a>

Drilled and tapped them...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=34drillandtapholesinbackplates.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/34drillandtapholesinbackplates.jpg" border="0" alt="Photobucket"></a>

And trial-fit the guides, screws, and backplates:

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=35trialfitbackplatetorailguide.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/35trialfitbackplatetorailguide.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=36trialfitbackplatetorailguide2.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/36trialfitbackplatetorailguide2.jpg" border="0" alt="Photobucket"></a>

Next, I marked a centerline and drilled out the airframe holes...

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=37markcenterlineanddrillrailguideho.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/37markcenterlineanddrillrailguideho.jpg" border="0" alt="Photobucket"></a>

Scuffed up the adhesion area, and epoxied the backplate in place:

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=38scuffupbackplateadhesionarea.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/38scuffupbackplateadhesionarea.jpg" border="0" alt="Photobucket"></a>

<a href="https://s124.photobucket.com/albums/p10/GatorFanFL/?action=view&current=39epoxybackplateinplace.jpg" target="_blank"><img src="https://i124.photobucket.com/albums/p10/GatorFanFL/39epoxybackplateinplace.jpg" border="0" alt="Photobucket"></a>

 

[rocketkyle]

looks nice, but 1 question... How are you going to get the fincan into the body tube with the backplate for the rail guides in there? I love the Competitor series, keep up the good work.