Estes DARC-1, #7307 Build Part 6, Cutting The Launch Lug Slot

This could be the most difficult part of the build. The plastic at the nose of the body is thick! Be prepared to take some extra time to get a good fit of the launch lug.

 

On the left - the raised "nub" for the launch lug to pass through.

I've already drawn around the sides with a sharp pencil.

A knife score is started around the raised area thinking it would leave a hole when cut off.

The plastic is thick. There was no hole when the raised plastic nub is cut off.

I built two kits. On the right is the first try at cutting through the plastic wall with a knife. 

On the second build I tried two different ways to drill into the plastic. These holes at either end were joined with more knife cuts.

Starting by spinning a knife tip or a very small hand-turned drill bit. A small hole was spin drilled to make an opening for a rat tail diamond file. The file kept the ends round as the holes were enlarged.

In the left side picture - the long launch lug is seen peeking through the lug hole. More plastic has to be removed for it to pass through.

The rat tail file is used again at approximately the same angle that the lug will be when slid in with the interior mount. At this angle, the file will remove tapered plastic from the outside top and the inside bottom around the hole.

I've drawn up a PDF that better shows the inside and outside plastic wall taper recesses to be shaped. The PDF is available to Patreon supporters. 

Email me at oddlrockets@bellsouth.net and ask for the Darc-1 PDF.

I recommend this PDF pattern for this build.