Estes Cosmic Interceptor Build, Part 27, Launch Lugs

I know - I'm pre-painting almost everything. On this complicated a build, you'll have trouble getting spray paint into all the inside and covered areas. When you paint over a glue area, the surface has to be carefully scraped or sanded so the glue can soak in and adhere the parts.

 

The lugs were pre-painted white.

The bottoms are areas of the lugs are touching the cardboard and won't get any paint.

It helps to use a log tweezer to set the lug under the T piece.

Note the two glue lines.

One line contacts the body tube, the other touches the wing near the root edge.

The lug gluing areas on the model are sanded using 400 grit wrapped around a Q-tip. Sand an area a little shorter than the length of the lugs.

Here's the lugs in line.

I won't be applying glue fillets, there would be bubbles when the glue dries.

Because the glued areas had the surface roughened and paint removed, the bond is plenty strong.

Estes Cosmic Interceptor Build, Part 26, Fitting The Vanes

Don't glue the vane assembly in place. The body of the rocket is mostly white, the vane assembly is black. 

Paint the vanes and body separately, then glue the vanes under the tube intake.

Notice the high (middle) vane is touching the intake body tube while the smaller vanes have a gap.

The largest center vane was trimmed with a new razor blade.

Cutting into the corner, 

Shave a little and check the fit.

Here the fit is much better, all the vane forward edges are contacting the intake tube.

Estes Cosmic Interceptor Build, Part 25, Gluing The T & V Pieces

The instructions have you glue the vertical V piece (rudder) before gluing on the horizontal T pieces. Wait to glue the V piece. Even though the paper marking guide fit well, the V rudder piece ended up a little off the pencil line. I ended up visually centering the V piece between the glued in T pieces.

   

No glue yet - 

Set the T piece in it's slot, resting the tapered side on the body tube.

Trace around the tapered end outlining in pencil on the body tube.

Scrap away any paint until you can see the bare body tube. 

Scrape inside the pencil lines.

Then glue on the V rudder piece even with the tube end. 

Note the taper. You might be tempted to glued it flipped the other way.

Estes Cosmic Interceptor Build, Part 24, Fitting The "T" Brace

The T pieces fit into a notch in the vertical S pieces. They sit high on the body tube and have to be sanded to fit. The T pieces should end up flat, parallel to the face of the large wing. 

The upper picture shows the start of the sand, a small bit has been sanded away. 

The bottom picture shows the angle sanded down so the T piece sits flat.

You can get a better fit against the body tube.

I wrapped some 220 grit around a dowel to make the flat root edge curved.

On the left, the curve has been sanded.

The right side picture shows the new root edge fit against the body tube.

You might have noticed the pre-painting of the areas inside and under and T pieces. If glued together it would be hard to get white paint to cover the hidden surfaces.

Estes Cosmic Interceptor Build, Part 23, Wing Gluing

These large wing fins were difficult to glue on!

They remind me of the large Orbital Transport or even the Gyroc fins. You think they are tacked on then the weight of the fin pulls it off the body tube.

Looking from the rear - 

Make sure the fins are perpendicular before the glue sets up.

This fin required some tweaking.

On the left is an example of wood glue placed down the root edge.

TIP: Even out the glue line before placing on the body tube.

In the left side picture, notice the "V" formed by the thumb and index finger. Hold the V and run your fingers down the glue.

You should end up with an even glue line as shown on the right side. When pressed on the body tube fin line, there will be a cleaner joint with less glue squeezed out. 
 

New Odd'l Rocket?

Which head (nose cone) do you prefer? Please comment below.

The newer head (on the left) is a bit like the Lost In Space robot, clear with details inside. 

The original design resembles a robot toy from early sci-fi.

They are different! If I can get prototypes built, then comes flight testing.

If a kit is produced, they will be more colorful.

Estes Cosmic Interceptor Build, Part 22, Root Edge Fit

The supplied fin marking guide fit!

The root edge contact positions (two on each of the main wing fins) had the filler/primer scraped off for better adhesion. 

A dry fit of the wings showed the lower root edge not making complete contact. The upper root edge was good.

The root edge was sanded with 320 grit on a block until the fin made full contact down the fin / body tube joint.