This is a kit of parts that can be printed up to make a BT 80 Based model rocket version of the mighty saturn V . All the neatness of the awesome 1/100 scale Estes Saturn V with a lower cost to fly, and a less expensive and time consuming build. This is not a complete kit, You will still need to use standard model rocket parts to complete a flying version of this rocket. You will need lengths of BT80 BT60 BT50 And BT20. You will also need a 24" parachute, Shock Cord, Kevlar Cord, thrust ring, Centering Ring, and Engine hook. Various other building supplies such as cardstock, pennies, BB's , and thick cardstock will be used. This will be atleast a skill level 4 kit.
06/02 Added a nosecone and coupler for SKYLAB Variant .
Please take the time and check out my other model rocket things.
1) Cut all body tubes to length . Tube Lengths BT80 - 16.25" 413mm,
BT60 - 3.42" 87mm ,BT50 - 1.18" 30mm , BT20 - 9" 229mm
2) make all marks with a pencil
3) Write fore at one end of each tube, And write Aft at the other
4) Make 1 full length straight line on all body tubes.
5) Mark BT80 at 5.5625", 12.125" From the aft end.
6) Mark BT20 at 0.75", 2.5", 8.75" From the aft end.
7) Mark BT60 at 2.39" 61mm From the aft end.
8) Smear superglue in a ring about 0.5" 13mm deep in the fore end of
the BT80, set aside to dry.
9) Smear superglue in a ring about 0.5" 13mm deep in the Aft end of
the BT20, set aside to dry.
10) Use a scrap piece of wood to apply a bead of white or wood glue
2.5" deep into the aft end of the BT20
11) Insert the thrust ring into the aft end of the BT20 to a depth
12) Cut a 1/8" slot at the 2.5" mark. Apply a drop of super glue over
the slit, and place engine hook into slit. Tape the Engine hook into
place with masking tape around the Body Tube.
13) Make a small .0625" 2mm notch in bt50 to bt20 centering ring
14) Tie the Kevlar cord around the fore end of the BT20, just rearward from the 8.75" Mark.
15) Apply glue to the BT20 just forward of the 8.75" mark, Place the centering ring over the other end of the kevlar cord, and push onto
the body tube gluing into place with the kevlar seated in the notch.
16) Cut BT80 to BT20 centering rings from laminated or thick cardstock. Cut a thickened piece of cardboard appropriately sized for the launch lug. And Glue to the launch lug and set aside to dry.
17) Glue the cardstock rings one on each endof the BT20 one at 8.75" one
at 3/4" set aside to dry. Make sure cord is through center of the Forward ring.
18) Emboss the cardstock Wraps with a Ball point pen that is dry, or some other suitable tipped instrument on the correct side.
19) Cut The wraps out of the cardstock.
20) Apply wraps where appropriate on the tubes with the Correct side facing out. Use center line to position .
21) Tie a bead 6" from the end of the BT20 onto the kevlar cord. This should help to prevent zippering at ejection.
22) Apply white or wood glue into the aft end of the BT80 around the inner perimeter at 8" deep .
23) Carefully insert the Engine Tube assembly into the aft end trying to keep the kevlar from contacting the glue. Insert the centering ring about half way , and apply another bead of glue just inside the aft end. Finish inserting the aft centering ring into the BT80 to a depth of 0.25". Wipe off any glue that may have gotten onto the kevlar cord. Set aside to dry.
24) Ues epoxy to glue 75 BB's into the command module nose cone. Weight of the BB's should be approximately 0.9 OZ.
25) Use epoxy or an appropriate glue to your plastic,to glue the recovery ring into the base of the BT80 - 60 adapter.
26) Glue the large adapter into the BT60 with epoxy. Glue the small adapter into the other end.
27) Use superglue or epoxy to glue the Fin shrouds onto the aft end of the BT80.
28) Glue Launch lug assembly onto the BT80 half way between the Fins and the next wrap along the centering line.
29) Glue the small plastic pieces to there various places on the bodies.
30) Prime and paint base coat of white on lower and upper assemblies and nosecone as desired.
31) Mask and paint appropriate areas of black, and silver.
32) You can either paint the BT50 silver, or apply the wrap to it. At your choice.
33) Glue BT50 onto the upper assembly, Glue nosecone into the upper assembly.
34) Attach upper and lower assembly with a shock cord .
35) Assemble and attach atleast a 24" parachute.
36) At your choice you can either glue the engine assembly to the base with epoxy, or fly without it attached.
37) Print out on sticker paper or decal film the decals from estes sets 2157, 2001, or k-36. Use a scale of 66%
38) Apply decals where appropriate.
39) Enjoy and Fly in good health and wishes.
40) There is no warranty implied or specified in your choice to build this kit. Please feel free to print and assembly as many as you would like . If you have any great ideas for improvement or want to add to the 3d printed rocketry world, please do so. If you feel the need to send the creator a gift for the many hours creating the files used , please contact me through thingiverse.