Discount Rocketry ModelRockets.us Expert 4.0 Series User manual

Expert Series 4.0 Crayon Rocket
Assembly Instructions

Fin Can Assembly
Step 1 - Mark the motor tube
3¼” from one end.
Step 3 - Place marked end down
and lock a fin into the slot at the
top of the bottom centering ring.
Step 5 - Slip another centering
ring over the top end of the
motor tube while holding the
assembly together.
Step 2 - Insert the motor tube into
a centering ring until the mark is
at the edge of the centering ring.
Step 4 - lock all the other fins in
the same way.
Step 6 - With both shock cord
holes of the centering rings
aligned, push the top centering
ring down and lock all the fins
together.

Fin Can Assembly
Continued…
Step 1 – Re-check and adjust
the motor tube to 3¼” from end
to the edge of the centering ring
and tighten all the parts of the
assembly together.
Step 3 - Apply a glue fillet the
top centering ring where it
contacts the motor tube.
Step 2 – Apply a glue fillet to the
inside of each fin where it contacts
both the centering rings and the
motor tube.
Step 4 - Apply a glue fillet the
bottom centering ring where it
contacts the motor tube.
Set aside to dry.

Launch Lug Assembly
Step 1 - Apply a bead of glue on
one standoff along the top
shorter surface.
Step 3 - Align the launch lug
straight to the standoff.
Step 2 - Attach the launch lug to
the standoff.
Step 4 - Do this for both launch lug
assemblies and set aside to dry.

Launch Lug Attachment
Step 1 - Apply glue to the
bottom of the first launch lug
assembly.
Step 7 - Press the launch lug
assembly firmly onto the crayon
tube.
Step 9 - Insert the tabs on the
bottom of the launch lug
assembly into the top alignment
holes of the crayon tube.
Step 2 - Insert the tabs on the
bottom of the launch lug assembly
into the bottom alignment holes of
the crayon tube.
Step 8 - Apply glue to the bottom
of the second launch lug assembly.
Step 10 - Press the launch lug
assembly firmly onto the Crayon
tube. Set aside to dry.

Nose Assembly
Step 1 - Place the largest
bulkhead on top of the smaller
bulkheads and insert the t-nut
into the center.
Step 3 - Screw the screw eye
into the opposite end and insert
the bulkhead into the nose cone.
Step 5 - Screw the screw eye all
the way through the nut and
insert through the flat washer.
Step 2 - Hammer the t-nut into the
forward bulkhead until flush.
Step 4 - Pull the bulkhead to the
rear inside lip of the nose cone and
remove the screw eye.
Step 6 - Insert the screw eye
assembly into the next largest and
then the smaller bulk head last.

Nose Assembly
Continued…
Step 7 - Screw in the screw eye
and bulkhead assembly into the
t-nut tightly.
Step 8 – The bulkhead assembly
will secure itself onto the rear lip
of the nose cone.

Main Tube Assembly
Step 1 - Tie a knot in one end of
the kevlar shock cord.
Step 3 - Insert the other end of
the shock cord through the top
end of the motor tube.
Step 5 - Apply a tick bead of
glue to the inside of the crayon
tube just below the end of the
fin slots.
Step 2 - Insert the shock cord
through the bottom centering ring
and then through the top
centering ring.
Step 4 - Pull the shock cord
through the bottom of the motor
tube.
Step 6 - Push the fin can assembly
all the way into the crayon tube
until the fins stop at the fin slots.

Main Tube Assembly
Continued…
Step 7 - Apply a glue fillet
between the inside of the
crayon tube and the bottom
centering ring.
Take care to not apply glue to
the shock cord hole and knot.
Step 8 – Set aside to dry.

Recovery and Final
Assembly
Step 1 - Pass the shock cord
back through the bottom of the
motor tube and out of the top of
the crayon tube.
Step 3 - Pull and check that the
knot is tight.
Step 5 - Pull the parachute lines
straight to the end and tie a
single knot in the end of the
parachute lines.
Step 2 - Align the ends of the
Kevlar and elastic shock cords and
tie a single overhand knot.
Step 4 - Align the ends of the
parachute at the shroud lines.
Step 6 - Pass the end of the elastic
shock cord through the loop at the
end of the parachute lines.

Recovery and Final
Assembly Continued…
Step 7 - Tie the elastic shock
cord to the screw eye on the
nose cone with a double knot.
Step 9 - Insert the parachute
and shock cords in the top end
of the crayon body tube.
Step 11 - Apply a bead of glue
to the fins and launch lug
assemblies where they intersect
the crayon body tube.
Step 8 - Fold the parachute and
roll parachute around the
parachute lines. Do not twist the
lines while rolling.
Step 10 - Insert the nose cone in
the body tube. Sand the bead on
the nose cone shoulder if it is to
tight to eject during recovery.
Step 12 - Smooth the glue into a
fillet using a clean finger.

Recovery and Final
Assembly Continued…
Step 13 - Wrap some layers of
masking tape around the tail
cone shoulder.
Step 15 - Test that the fit is
tight so that the tail cone does
not separate during flight.
Step 14 - Press the tail cone into
the bottom of the crayon tube.
Your crayon rocket is complete!
CAUTION: INSERT RECOVERY
WADDING INSIDE THE ROCKET
BETWEEN THE PARACHUTE AND
MOTOR TO PREVENT THE HEAT OF
THE EJECTION CHARGE FROM
DAMAGING YOUR PARACHUTE
WHILE FLYING!!!