Booster 55 Rocket Build, Finished

Sometimes less is more.
It's a classy looking model with just enough gold trim.
This is an example of what I've mentioned before - two major colors and a third color for trim.

I added one wrap around the top of the roll pattern. Placing the roll pattern high makes the model seem taller.

The fin can is epoxied in the body tube with the lug centered between two fins.
Usually I won't do a tri-fold mount but there wasn't anywhere to attach the Kevlar line. A long 1/4" wide rubber shock cord was glued into the mount.
A 12' Odd'l parachute rounds out the build.

While I could launch this with a D12-7, I'll probably end up using C engines and a 20/50 adapter.

Booster 55 Rocket Build, Part 6, Upper Body Gold Trim

The rocket needed something else at the top. I decided on a roll pattern.

I made a paper wrap and folded it into four sections. The roll pattern vertical bars will center above the fins. After a few measurements I decided on eight 1/4" wide lines.

A wrap of tape will align the tops of the trim bars.

The aluminum angle was set on the body tube and lines drawn onto the masking tape wrap.

The gold trim bar top was set against the tape edge. Looking down the body tube you can vertically align them with the fins.

After the first four bars were set the remaining four were visually set between them.

Booster 55 Rocket Build, Part 5, Fin Gold Trim

The body tube and nose cone were shot with primer/filler first and sanded.
White coats followed with sanding in between coats.
The fin can won't be painted, this shows a dry fit after the first sanded white coat.

The model will be black and white with gold Trim Monokote for the third color trim.

I traced around the fin onto some card stock.
I always like the simple fin decor of the Estes Omega.

Cut out the card stock piece to use for a cutting template.

The trim piece was set down using my knife blade so I wouldn't get finger oil on it.

Booster 55 Rocket Build, Part 4, Launch Lug and Standoff

The rear engine locking ring is wider than the BT-55 above it.

The 3/16" launch lug will require a standoff so the launch rod will clear it. This rocket can use 24mm engines so I used the larger 3/16" lug.

I used a small dowel for the standoff.
It reminds me of the old Estes C-Rail standoffs. (The old-timers will know what I mean.) 
The bottom of the dowel was sanded flat for a little more gluing area on the tube.

The tube and nose cone were already hit with filler/primer.

I scraped off the primer where the lug standoff will be glued.
TIP: Try scraping with the back side of the knife blade. You won't dull the sharp cutting side.

Here's the finished lug with standoff.
Fillets of Titebond No-Run, No-Drip glue followed.

Booster 55 Rocket Build, Part 3, Nose Cone Seam Filling

The nose cone is a new item from Apogee so the molds are new. There was very little molding seam to fill.

I got out my Dollar Tree store bottle of Super Glue. They are usually 2 for $1.00. It's medium thickness.

On the left you can see the slight seam left after sanding.

On the right is the raised bead of Super Glue. Apply enough so the bead of glue will end up a little higher than the surface of the nose cone. Do one side at a time and let the first side dry facing up and horizontally. Be careful, the glue can run!

The glue dries hard and clear. I used a diamond file to knock down the bulk of the bead. 220 grit followed then 400 grit.

On the right is the finished fill ready for grey filler/primer.

Booster 55 Rocket Build, Part 2, Removing the Staging Funnel

This was the trickiest part of the build. The funnel might be fine at ejection but the bulk of the charge would be compressed into a 1/4" hole.

I got out my ancient Dremel tool and attached a sanding drum. Most of the funnel was ground out.

On the left is the funnel after grinding. Most all of it was melted and easily cut out with a knife.
When is was removed I could see the glue on the side walls. I might have been able to knock out the funnel with a hammer and dowel. But then again, I might have broken the fin can.

Booster 55 Rocket Build, Part 1, Parts

This should be an easier one but still interesting. I'll be adapting the plastic 55 Booster to a 55 tube.
It's a very inexpensive build made from clearance kit parts, leftovers and a free nose cone from Apogee.

The parts:
A BT-55 stolen from an Estes clearance Monarch kit.
The nose cone is a new 55 size from Apogee.
The 3/16" launch lug will need a standoff, there's a small dowel next to it.
An Odd'l Rocket parachute (what else?)
Rubber shock cord from a Little Joe II kit.
The BT-55 Booster picked up for a dollar at Hobby Lobby.

The 55 Booster is assembled. You won't need the upper adapter ring.

At the top is a length of BT-55 and will have to be removed.
Score through the tube and peel it off.







The tube was glued on pretty well

Notice the duct "funnel" that directs the booster engine flame into the upper stage engine.









It took a few minutes of sanding to clean off the shoulder and get a slip fit into the BT-55 tube.

Estes Booster 55, Part 2

The "key tabs" on the fins slide into the long slots in the lower plastic side of the tube. They are tight!
When both tabs are in place the fins is slid up until it stops.
NOTE: Be careful not to grip the BT-55 tube at the top too tight, you can bend it fairly easily.

The engine locking ring is spun on until it stops at the base of the fins. The ring also locks the low end of the fins in place. A very well designed accessory.

Here's the top, you can see the inside of the BT-55 tube.

The is a plastic "funnel" that directs the hot propellant pieces into the 18mm engine in the second stage.

Here's the ring that replaces the ring from the RTF kit. You can see the screw threads that fit the upper engine mount.

As John Boren said on a forum, the fit of the "Stager" ring is pretty loose in the Booster 55 unit.
This might be why the few two stage rockets I've flown have veered off when the second stage ignites.

Estes Booster 55, Part 1

I've read on the forums that Hobby Lobby is blowing out the Estes Booster 55 and Booster 60s for $.99. The Hobby Lobby I go to (for engines with the 40% off coupon) have them at the regular retail price of $7.99.
Today I was on the other side of town and stopped by a different Hobby Lobby store. There was one Booster 55 left. And for $.99 cents I couldn't pass it up!

When I cut through the tape at the top I thought something was missing. They could have packed the parts in a box half this size!

Here's what you get - 
A plastic tube with a BT-55 set into the top. The plastic low end has keyed slots for the root edge attachment.

Four Nike Smoke shaped fins.
A locking ring for the bottom and a locking ring for the upper stage rocket. The upper locking ring (called a "Stager" online) replaces the engine locking ring on the upper stage rocket.