DynaStar Grappler User manual

Page 1
Grappler Parts List
P/N Description Qty
10092 Yellow Engine Mount Sleeve (AS-24/4.00) 1
10097 Engine Mount Tube (AT-24/15) 1
10197 Airframe Tube (AT-66/18) 2
13031 Centering Ring (CR18-24) 1
13035 Centering Ring (24-29) 2
13044 Airframe Coupler (AC-66) 1
15027 Die-Cut Ring Set CR24-66 1
13056 Launch Lug (1/4” X 3”) 1
15540 Die-cut balsa fin sheet 1
19480 Plastic Nose Cone PNC-66A 1
24041 Standard Engine Hook 1
23011 Parachute Reinforcement Rings (8) 1
29500 Parachute Shroud Line (21.3 feet) 1
29117 32” Plastic Parachute canopy 1
29506 300# Test Kevlar®Shock Cord (8 ft) 1
31066 Grappler Instruction Sheet A 1
31067 Grappler Instruction Sheet B 1
37020 Grappler Tube Marking Guide Sheet 1
41029 Printed Decal Sheet 1
Other Tools and Materials Needed
• Scissors
• Hobby Knife
• Pencil
• Carpenter’s Wood Glue (or White Glue)
• CyA Adhesive (medium viscosity)
• Masking Tape
• Sandpaper (200 and 400 grit) & Sanding Block
• Aluminum “Angle” to draw lines on the tube
• Ruler
• Wood filler or sanding sealer to smooth balsa fins
• Paint Brush
• Spray Paint
• 24mm Spent Engine casing to insert engine block.
• Long wood dowel to spread glue deep inside tubes.
• 3 1/4 inch wooden dowel
Mid-Power
Model
Rockets
1130 Elkton Dr., Suite A
Colorado Springs, CO 80907 USA
web site: www.DynaStar-Rockets.com
Skill Level 2 – Previous Experience Suggested
The Grappler is about the biggest model rocket you can
make that still is under 1-pound in weight at lift-off. This
is important, because you don’t need FAA permission to
launch it. That gives you high-power thrills with inexpen-
sive low-power rocket engines. The Grappler is easy to
build, uses readily available “D” and “E” size rocket mo-
tors, and is a real eye-catching model that is sure to get
you noticed whenever you launch it.
While this is a big rocket, it is easy to build: it is only
ranked as a skill level two in difficulty. It can be assem-
bled by anyone that has built any other model rocket kit.
GRAPPLER
GRAPPLER Kit #5032
Sheet A - P/N 31066

Page 2
�
Grappler Rocket Assembly
1. Using 400 grit sandpaper, fine sand the
balsa die-cut sheets before removing the fins.
Carefully remove all the pieces from the balsa
sheet by freeing the edges with a sharp hobby
knife.
2. Group the three fins together, and gently
sand the edges as shown in the illustration.
3. You can apply sanding sealer to the
surfaces of the balsa fins. Coat both sides at
the same time to minimize the chances of the
fins warping. Do not allow the sanding sealer
to get on the root edge of the fin. This could
prevent the fin from bonding well to the body
tube when it is glued on later in step 17. Set
them aside to dry completely. When they are
dry, sand the sealer smooth until you get a de-
sirable surface finish. You may need to repeat
this step several times depending on the level
of quality you wish to achieve.
4. Mark a line on the outside of the motor
mount tube 2 1/4 inches (57mm) from one
end. This end will be the aft end of the rocket.
Make this line about 1/8 inches (3mm) long as
the picture shows. Take a hobby knife and cut
a 1/8 inches (3mm) long slit in the engine tube
along the line as shown in the picture. Insert
one end of the motor hook into this slit.
5. Make a mark 1 1/2 inches (38.1mm)
from the rear of the engine tube. Locate the
yellow airframe sleeve. Apply a layer of glue
around the tube for a 2 inch length, forward
of the mark that you made. Slide the yellow
sleeve over the engine hook and onto the
engine tube until the rear end of the sleeve is
lined up with the mark. Apply a fillet of glue to
both ends of the sleeve (Be sure that the en-
gine hook remains perpendicular to the engine
tube).
6. Now mark 1 1/8 inches (29mm) from the
rear of the engine tube. Find one of the large
green rings that fits over the 24mm diameter
engine mount tube. Make a thin layer of glue
around the engine tube behind the mark you
made. Take the green ring, slide it over the
engine hook, and then onto the engine tube
until the rear end of the ring is lined up with
the mark you made (Be careful of the hook as
above).
7. Remove one of the three large centering rings
from the die-cut card sheet and apply a bead of
wood glue 71/2 inches (17.8 cm) from the front end
of the engine tube, Slide the cardboard centering
ring into the bead of glue. Check to be sure the ring
is aligned straight on the tube. Allow the glue to dry.
Engine Hook Size “A” Length
D-Engine 2-1/4” (57mm)
Do NOT use the Estes E9 in this rocket.
It doesn’t have enough thrust to safely lift
this big rocket kit.
1/8” (3mm)
1-1/8” (29mm)
7 1/2” (17.8m)
1-1/2”
Yellow Sleeve

Page 3
8. Remove a second large centering ring
from the die-cut card sheet. Apply a bead of
wood glue around the engine mount tube, 1/2
inch (13mm) from the aft end. Slide one of
the cardboard rings onto the engine tube over
the engine hook and into the bead of glue.
Check to be sure the ring is aligned straight as
shown.
9. Make a mark 1/2 inch (13mm) from the
front of the engine tube. Find the other large
green ring that fits over the 24mm diameter
engine mount tube. Cut a notch on the inside
with a hobby knife. Tie the yellow Kevlar®
shock cord around the front end of the engine
mount tube. Apply a thin layer of glue in front
of the mark. Slide the green ring over the
shock cord and onto the tube, into the glue,
and up against the mark. The shock cord
should fit tightly up against the ring.
10. Engine block installation: Using wood
glue, glue the smallest green ring (the en-
gine block) into the forward end of the engine
mount tube. Push it in using a long wood
dowel until it rests against the top of the en-
gine hook. Once it is in place and dry, add a
fillet of glue around the front edge of the green
engine block using a 3 1/4 inch wooden dowel.
11. After the glue on the engine mount is
dry, put a fillet of glue on each side of all three
of the centering rings. These rings take a lot of
stress at engine ejection, and you must make
sure to have a good glue bond (Note: it is not
necessary to use epoxy. Wood glue is plenty
strong for this application). Allow the glue to
dry completely before proceeding to step 11.
12. Test fit the engine tube assembly into
one of the AT-66 tubes. If it is too tight, sand
the centering rings slightly. Apply wood glue
7 inches (178mm) in from the aft end of the
body tube. Insert the engine mount, and push
with one motion until the middle centering ring
makes it about 3 inches (76mm) past the aft
end of the body tube. Quickly apply wood glue
inside the body tube 1/2 inch (13mm) from
the aft end. Immediately push the motor tube
in until the aft end is flush with the body tube.
Apply additional wood glue to the exposed
centering ring/body tube, making another fillet.
Stand tube upright with engine hook hanging
over the edge of table until the glue is dry. This
prevents excess glue from dripping forward in
the tube.
1/2” (13mm)
Cut a notch for
the shock cord.
Pull
Tight
Glue fillets on both sides of rings.
1/2” (13mm)
7” (17.8 cm)
Smear glue around inside of tube. Smear glue after partially
inserting tube.
Edges of tubes
should be even.
Sheet B - P/N 31067

Page 4
13. Thread the shock cord through the
remaining cardboard centering ring. Then slide
it into the front end of the body tube, and then
over the forward end of the engine tube. Push
it until it rests up against the green ring. Add
a fillet of glue to the front side of the centering
ring at the centering ring/body tube joint and
also at the centering ring/motor mount tube
joint. Place upright on a table to allow the glue
to dry.
14. Take the red AC-66 Airframe Coupler
and test fit it into the front end of the mo-
tor mount assembly. Mark the coupler with
a pencil 2 inches (51mm) from one end,
which will be the forward end. Run a bead of
glue around the coupler on the rear half and
smooth it out with your finger. Now, push and
turn the coupler as you insert it into the for-
ward end of the tube. Stop when it gets to the
line. Wipe any excess glue away.
15. Apply wood glue to the exposed portion
of the coupler tube and quickly twist on the
upper body tube until the two body tubes are
butted-up against each other. Allow the glue
to dry.
16. Cut out the tube marking guide from the
pattern sheet (see page 8). Wrap the guide
around the aft end of the bottom white body
tube and tape the ends together. Mark a small
line at each of the arrow points. Remove the
marking guide.
17. Using a your metal angle tool (a door
frame will work, but it is not recommended on
large diameter tubes), draw a pencil line down
the outside of the body tube at each pencil
mark. Label the launch lug line so you don’t
glue a fin in the wrong position.
18. Lightly sand the area along which the
fins will be attached; just enough to take the
“sheen” off the tube. Apply a very thin layer of
glue to the root edge of one of the fins. Allow
the glue to dry slightly for five minutes, and
then attach it along one of the lines on the
body tube, as shown in the illustration. Each
fin is attached so that it is flush with the end
of the tube. Make sure the fin is straight along
the tube. Allow the fin to dry before proceeding
with the next fin. Repeat this step two more
times as you attach the other two fins.
Glue fillet on both inside and outer perimeter.
2” (5.1 cm)
Shock cord
Shock cord
Fin
Note the wood
grain direction.
YES NO

Page 5
19. Apply a bead of wood glue to both
sides of each fin-body tube joint. Pull your fin-
ger along the joint to smooth out and remove
the excess glue. Lay the tube horizontally
while the glue dries.
20. Using wood glue, attach the launch
lug to the tube on the pencil line; position it
so that it is flush with the seam where the two
body tubes meet. Allow the glue to dry. Apply
a bead of wood glue to both sides of each
launch-body tube joint. Pull your finger along
the joint to smooth out and remove the excess
glue. Lay the tube horizontally while the glue
dries.
21. After all the glue has completely dried,
you may now paint your Grappler model
rocket (Note: you can temporarily put the nose
cone on the white body tube while you paint
the rocket).
Roll a piece of paper and insert it into the
aft end of the body tube so you can hold the
model while painting it. For best results, paint
the model with primer before using the final
paint colors. Follow the directions on the paint
can, and always paint outdoors with the wind
against your back. Let the paint harden at
least 24 hours before proceeding.
22. Cut around the perimeter of the de-
cal with a pair of scissors. Peel off the paper
backing, and affix the decal in place on the
model. Use the picture on page 1 for decal
placement.
23. Tie the loose end of the shock cord to
the loop on the base of the nose cone using 2
overhand knots. Apply a little bit of the wood
glue onto the knot to keep it from coming
untied.

Front edge of launch lug even with tube seam.
www.DynaStar-Rockets.com
DynaStar is a brand of Apogee Components, Inc.
1130 Elkton Drive, Suite A
Colorado Springs, CO 80907 USA
DynaStar Mid-Power Model Rockets
P/N 41029
Nose Cone: paint “silver”
Fins: paint “silver”
Body Tube: paint “black”

Parachute Assembly
24. Carefully cut out the parachute canopy
along the dashed lines. Place one reinforce-
ment ring on each of the marked corners.
Take a sharp pencil or knife and poke a hole
through the plastic in the center of each ring.
25. Fold the shroud line in half, and cut at
the fold to make equal lengths; cut each piece
in half again to make a total of four lines of
equal length.
26. Pull each parachute line end through a
parachute reinforcement ring and tie using two
overhand knots. Repeat for all the corners as
shown.
27. Holding the parachute at the center of
its top, pull the lines together to even up the
ends. Thread the 4 looped lines through the
loop at the base of the nose cone. Take the
top of the parachute and pull it through all 4
string loops at the same time and then pull to
tighten the knot. This securely attaches the
parachute to the rocket.
28. Congratulations! Your Grappler is now
complete.
Launch Supplies Needed
To launch your rocket you will need the follow-
ing supplies:
u A model rocket launching system.
u Flame resistant recovery wadding.
u Recommended 24mm Diameter Rocket
Engines — see the motor matrix to the right.
�
Figure 1
Shroud line
Adhesive circle
a division of APOGEE ROCKETS
1130 Elkton Drive, Suite A
Colorado Springs, CO 80907 USA
www.ApogeeRockets.com
CAREFULLY CUT OUT ALONG DASHED LINE
CAREFULLY CUT OUT ALONG DASHED LINE
STEP 2
Press the circle firmly and attach second end to the
circle next to it on the same side of the parachute
(see Figure 2).
STEP 1
Carefully cut out parachute canopy along dashed lines.Take parachute
shroud line and cut into 3 equal lengths. Placing the end of each shroud
line over a circle at the parachute corners, secure line with adhesive
circle as shown in Figure 1.
Figure 2
STEP 3
Holding the parachute canopy
by the center of its top, pull the
lines together and try to even up
the ends.
STEP 4
Pass the parachute lines through the nose cone eye screw. Pass the canopy
completely through the loop ends of the parachute. Pull the lines tightly against
the eye screw and fix the knot in place with a drop of glue.
nose cone eye screw
Tape Ring
Poke hole through
each ring.
A
BC
Page 6
The above motor matrix was made using RockSim. Initial conditions:
slightly breezy (3-7mph wind), straight up launch angle. You can use
RockSim to find other motor combinations that will work well in the Grap-
pler rocket kit. Download the RockSim file for this kit at: www.ApogeeRock-
ets.com/grappler.asp
Motor
Type
Produced
by:
Estimated Altitude
(feet)
Estimated Altitude
(meters)
D12-5 Estes 329 ft 100.5 m
E15-7 Aerotech 1164 ft 354.9 m
E30-7 Aerotech 1178 ft 359.2 ft
The Estes E9 is NOT recommended for use in this rocket. It doesn’t have enough
kick to keep the rocket going straight up. It will make the rocket go horizontal, which
is very dangerous.
Motor Matrix: How High Will the Grappler Fly With Different Motors

Rocket Preflight
A. Loosely crumple and insert 8 sheets of
recovery wadding into the body tube.
B. Carefully fold the parachute and insert it
into the tube with the shock cord.
C. Insert the motor into the motor tube until
the motor hook holds it in place.
D. Insert and secure the engine igniter as
directed on the package the engines came
with.
Countdown and Launch Procedure.
Fly your rocket on a large field that isn’t near
any power lines, trees, or low flying aircraft.
The larger the field, the greater your chances
of recovering your rocket. The launch area
around the pad must be free of dry weeds and
brown grass. Launch only during calm weather
with very little or no wind and good visibility.
Always use a launch pad that includes a blast
deflector.
10. Remove the safety key from the launch
controller
9. Slide the launch lugs over the launch rod
to place the rocket on the pad. The rocket
should slide freely over the rod.
8. Attach the micro-clips to the igniter. The
clips must not touch the other or the metal
blast deflector.
7. Stand back from your rocket as far as the
launch wire allows (at least 5 meters - 15
feet).
6. Insert the safety key to arm the launch sys-
tem. The light (or buzzer) on the controller
should come on.
Give a loud countdown 5 ... 4 ... 3 ... 2 ... 1 ...
LAUNCH!
Push and hold the button until the engine
ignites. Then remove the safety key and place
the safety cap on the launch rod.
Misfire Procedure
Occasionally the igniter will burn, but the mo-
tor will fail to ignite. If this happens, the cause
is that the pyrogen on the igniter was not in
contact with the engines propellant. When an
ignition failure occurs, remove the safety key
from the launch controller and wait 60 seconds
before approaching the rocket. Remove the
old igniter from the engine and install a new
one. Make sure that the igniter is insert fully
into the engine and touches the propellant.
Secure the igniter as directed on the engine
package and repeat the countdown and
launch procedure.
1 2 3
45
Fold
Peak
Down.
Spike
Canopy. Lay Excess String
on Top of Canopy.
Roll Sides Inward.
Loosely Wrap Any
Excess String around
Canopy And Insert.
Hook securely latched over edge of the
rocket engine.
Page 7
Place wadding in first. Do
not compact too tight.
insert parachute last.
Always follow the NAR* Model Rocket Safety Code when launching model
rockets.
*National Association of Rocketry
**Kevlar® is a brand name of E.I. DuPont for their selection of aramid fibers.
Only DuPont makes Kevlar®
Make sure the clips don’t
touch each other, or the
metal blast deflector.

Page 8
Fin
Fin
Fin
Launch Lug
Fin Template
Use this template to make replacement
fins, just in case you break one off.
Note the wood grain direction!
Overlap
Visit Us Online at: www.Dynastar-Rockets.com
Tube Marking Guide Sheet
P/N 37020