Estes Thor Agena Build Part 14 Half Round Fairings

The instructions say to make the half-round tunnels from balsa.
It's easier to form, sand and seal these if made from hardwood dowels.

A 1/8" X 48" long dowel was cut into fourths for easier handling.

When sanding a round dowel to a half-round shape, it can roll. Even the slightest rolling can make the flat back of the dowel crooked.

For a reference, use the side of a pencil and rub a line down the entire length of the dowel. This is the side that will be sanded off.

Look down the dowel to be sure the line (and dowel) are straight!

The dowel was set down on a scrap of corrugated cardboard.
The sanding block is holding 100 grit sandpaper.
Using long strokes down sand off the pencil line.

When the pencil line is sanded off, redraw the pencil line over the new sanded flat area. Sand off the pencil area again. Continue until half the wood is removed evenly down the length of the dowel stick.



To help hold the dowel steady, a "trench" was pressed into a long ridge of the corrugated cardboard.





Four 12" dowels were sanded down.

Set them side by side to check the profile consistency.