Estes GBU-24 PAVEWAY III EST 1247 User manual

ESTES®INDUSTRIES
1295 H Street
Penrose, CO 81240
PRINTED IN CHINA
www.estesrockets.com
PARTS:
Locate the parts shown below and lay them out on the table in front of you. DO NOT
USE THIS DRAWING TO ASSEMBLE YOUR ROCKET.
ASSEMBLY TIP:
Read all instructions before beginning
work on your model. Make sure you have
all parts and supplies.
KEEP FOR FUTURE REFERENCE.
HELPFUL HINT: IF NOSE CONE/COUPLER FIT IS. . .
TOO
TIGHT
TOO
LOOSE
ADD
MASKING TAPE. SAND FOR FIT.
FLYING MODEL ROCKET KIT INSTRUCTIONS
EST 1247/2053
TEST-FIT ALL PARTS TOGETHER
BEFORE APPLYING ANY GLUE!
If any parts don’t fit properly, sand as required
for precision assembly.
Body Tube BT-55 (1)
(30374)
Die Cut Balsa Sheet (2)
(32218)
Centering Ring Card (1)
(30126)
Mylar Retainer
Ring (1)
(30168)
Green Engine
Block (1)
(30162-2)
Shock Cord (1)
1/8" x 18"
(38374)
Assembled 12” (30 cm) Parachute
(35801)
Plastic Tail Cone and
Adapter (1)
(60568)
Decal Sheet (1)
(60569)
Die Cut Balsa Sheet (1)
(32219)
SHOCK CORD
MOUNT
SECTION 3
SECTION 2
SECTION 1
SHOCK CORD
MOUNT
SECTION 3
SECTION 2
SECTION 1
FIN
FIN
FIN
FIN
TUBE MARKING GUIDE
MATCH LINES
UPPER TUBE MARKING GUIDE
GBU-24 PAVEWAYIII EST 2053
Operation Enduring Freedom
sticker (1)
(60586)
Nose Cone (1)
(60567)
Yellow Spacer Tool (1)
(35003)
Launch Lug (1)
(38178)
Body Tube BT-20 (2)
(30329)
Engine Hook (1)
(35021)
SUPPLIES In addition to the parts included in the kit you will also need:
SCISSORS PENCIL RULER FINE
SAND PAPER
(#400-600 GRIT)
CARPENTER’S
GLUE
MASKING
TAPE SPRAY
PRIMER
WHITE
SPRAY PAINT:
WHITE, OLIVE
DRAB, RED
PLASTIC
CEMENT
MODELING
KNIFE SPRAY
DULL
COAT
RAZOR SAW SILVER PAINT
PEN

1. ASSEMBLING ENGINE MOUNT
I" mark
(25 mm)
C. Stack like pieces and sand edges
smooth. Leave the edges square,
do not round them.
A. Fine sand balsa sheets. B. Carefully cut parts free with knife.
2. PREPARING FINS
1" mark
(25 mm)
1" mark
(25 mm)
A. Measure and mark Yellow
Sp acer Tool. B. Use scrap balsa to smear glue 2" (51 mm) inside engine mount tube. C. Push engine block into BT-20 engine mount tube with spacer tool up to mark. Remove
spacer tool.
E. Position Engine
Hook. F. Temporarily tape hook into place.
G. Carefully remove rings
from card. H. Apply glue above the 1" (25 mm) line. I. Slide mylar retainer ring onto engine mount tube up to 1" (25 mm) mark. Let
dry.
J. Place a pencil mark at 2 1/2" (64 mm) and
4 7/8 (124 mm) from end of engine mount.
Remove tape.
K. Slide a centering ring down to
the 2 1/2" (64 mm) mark.
Yellow Spacer
Tool
1/2”
(13 mm)
Rear
2 1/2 (64 mm)
4 7/8 (124 mm)
L. Slide a centering ring down to
the 4 7/8" (124 mm) mark. M. Apply glue fillets to both sides of each centering ring. Let dry.
GLUE
GLUE
GLUE
GLUE
GLUE
2"
(51 mm)
Scrap Balsa
Engine mount
Tube
Remove
Immediately
1"
(25 mm)
2 1/4"
(57 mm)
D. Mark engine mount tube at 1" (25 mm) and
2 1/4" (57 mm) from rear end. Cut 1/8" (3 mm)
slit at 2 1/4" (57 mm) mark.
Green Engine
Block
Mark
Yellow Spacer Tool
1/2"
(13 mm)
Rear

"LL"
3. MARKING BODY TUBES
SHOCK CORD
MOUNT
SECTION
3
SECTION
2
SECTION
1
SHOCK CORD
MOUNT
SECTION
3
SECTION
2
SECTION
1
FIN
FIN
FIN
FIN
TUBEMARKINGGUIDE
MATCHLINES
UPPER TUBE MARKING GUIDE
GBU-24 PAVEWAYIII EST 2053
4. PREPARE TAIL CONE AND ADAPTER
DISCARD
Sand edges smooth.
A. Test fit fin tabs in slots.
Sand as needed for
proper fit.
C. Check alignment of fins as
shown. Allow glue to set.
D. Stand rocket on flat table
until glue dries completely.
NOTE: Fin
shape and
tab location.
BT-20
Upper Body Tube
A. Cut out tube marking
guide.
B. Wrap tube marking guide around
upper body and mark four places.
C. Extend all lines entire length
of tube.
D. Place a pencil mark on the
larger tube for launch lug "LL".
A. Tail Cone and Adapter B. Using a razor saw, carefully cut off
ends and cut in half.
C. Sand edges smooth.D. Carefully saw off nibs. Sand away
excess plastic lip flush with surface.
Upper Body Tube
Top view
Door
Frame
Fin lines
Extend Launch Lug line
with pencil.
Main Body Tube BT-55 (1)
Cut in half.
NOTE: Fins must be attached
correctly for stable flight.
5. ASSEMBLING ENGINE MOUNT AND TAIL CONE
A. Use finger to smear glue 2 3/4" (70 mm)
inside rear of body tube.
B. Engine hook must line up with
launch lug "LL" line.
DO NOT CEMENT
TAIL CONE YET!
C. Insert engine mount inside body tube
and push into place with tail cone.
Remove tail cone immediately. Let dry.
D. Apply a glue fillet around ring and
body tube joint. Let dry.
E. Apply plastic cement around
inside of body tube. Align
Launch Lug line between
fin slots on tail cone. Push
tail cone into body
completely. Let dry.
Fin Slot
Engine Hook
Rear View
Fin Slots
MAIN BODY TUBE
Glue
Body
Tube
"LL"
Fins should project
straight from the body.
6. ASSEMBLING LOWER FINS
90˚
90˚
90˚
90˚
Tab
PLASTIC
CEMENT
"LL"
"LL"
Cut off.
2 3/4”
(70 mm)
Cut off.
GLUE
"LL"
B. Apply carpenter's glue to fin and tab
edge. Push fin into tail cone. Let dry.
Continue to assemble remaining fins.
Let dry.
GLUE
GLUE

ASSEMBLING FIN REINFORCEMENTS
7. ATTACHING SHOCK CORD & ASSEMBLING UPPER BODY TUBE
A. Mark body tube 3/4" (19 mm)
from end on each fin line.
3/4"
(19 mm)
B. Cut out shock cord mount.
SHOCKCORD
MOUNT
SECTION 3
SECTION 2
SECTION 1
SHOCK CORD
MOUNT
SECTION
3
SECTION
2
SECTION
1
C. Apply glue. Fold forward.
I. Tie loop 3" (76 mm) from
second shock cord mount.
Shock cord
3
2
1
GLUE
D. Apply glue. Fold forward.
GLUE
1”
(25 mm)
3
G. Put a bead of plastic cement in
the rear of body tube. Insert
adapter. Let dry.
E. Squeeze tightly and hold
for one minute.
F. Apply glue to shock cord mount and
place inside end of upper body tube.
Press firmly. Let dry.
H. Apply Plastic cement to forward
end of tube and insert nose
cone. Let dry.
3" (76 mm)
GLUE
A. Apply glue to edge of fin as shown and attach to
pencil line at the 3/4" (19 mm) mark. Let dry.
B. Assemble remaining fins. Let dry. C. Complete assembly. D. Fins must be straight.
8. ASSEMBLING UPPER FINS
GLUEGLUE
3/4" (19 mm)
NOTE: Fins must be
attached correctly for stable
flight.
J. Cut out second shock cord mount. Glue
and fold as before. Apply glue to shock
cord mount and then insert it into the large
body tube. Press firmly. Let dry.
Second shock cord mount.
PLASTIC
CEMENT
THREAD SHOCK
CORD THROUGH
ADAPTER.
PLASTIC
CEMENT
A. Align reinforcement with fin.
Mark edge with pencil.
B. Smear glue on fin as shown
line. Apply reinforcement.
GLUE
C. Repeat steps A & B and apply
reinforcement to other side
of fin.
D. Repeat steps to apply
reinforcements to remaining
3 fins. Let dry.
COMPLETED FIN ASSEMBLEY
90˚
90˚
90˚
90˚
Fin Reinforcement

ROCKET PREFLIGHT
E. Wrap lines loosely. Insert
parachute, shock cord,
then upper assembly.
A. Insert four squares of loosely crumpled
recovery wadding into rocket body tube.
NOTE: Use Estes wadding (EST 302274) only.
C. Fold. D. Roll.B. Spike.
B. Tip must touch
propellant.
E. F. Insert engine.D.C.
A.
PAINT SCHEME First spray rocket with white primer, let dry
and sand. Repeat until rocket is smooth.
Follow the paint scheme on the package.
When paint is dry, peel decals one at a time
from backing sheets and apply where shown.
Rub down to remove bubbles.
*Optional - Spray a dull coat over
the entire rocket when complete.
ENGINE PREP
To avoid serious injury,
read instructions & NAR
Safety Code included with
engines.
PREPARE YOUR ENGINE
ONLY WHEN YOU ARE
OUTSIDE AT THE LAUNCH
SITE PREPARING TO LAUNCH!
If you do not use your prepared
engine, remove the igniter before
storing your engine.
9.ATTACHING LAUNCH LUG AND APPLY FILLETS
A. Measure 3/4" (19 mm) from end of body tube and
mark. Glue launch lug on the launch lug line "LL".
B. Apply glue fillets to all launch lug and fin/body
joints. Smooth with finger. Let dry.
C. Apply fillets to main fins/ body tube using plastic
cement. Smooth with finger. Let dry.
A.Loop shroud lines. B. Push through shock cord loop. C. Loop parachute through shroud lines. D. Pull tightly.
10. ATTACHING PARACHUTE
3/4"
(19 mm)
"LL"
GLUEGLUE
GLUEGLUE
GLUEGLUE
A.
B.
C.
PLASTIC
CEMENT
Shock Cord loop.
Shock Cord loop.

COUNTDOWN AND LAUNCH
FLYING YOUR ROCKET
Choose a large field (500 ft. [152 m] square) free of dry weeds and brown grass. The larger
the launch area, the better your chance of recovering your rocket. Football fields and
playgrounds are great. Launch only with little or no wind and good visibility.
Always follow the National Association of Rocketry (NAR) SAFETY CODE.
MISFIRES
TAKE THE KEY OUT OF THE CONTROLLER. WAIT ONE MINUTE BEFORE GOING
NEAR THE ROCKET! Take the plug and igniter out of the engine. If the igniter has burned,
it worked but did not ignite the engine because it was not touching the propellant inside
the engine. Put a new igniter all the way inside the engine without bending it. Push the
plug in place. Repeat the steps under Countdown and Launch.
NAR Safety Code
NO DRY
GRASS
OR WEEDS
PRECAUTIONS
© 2003 Estes-Cox Corp. All rights reserved. PN 60570 (3-02)
KEY ALWAYS OUT UNTIL
FINAL COUNTDOWN!
LAUNCH SUPPLIES
(sold separately):
• Porta-Pad®II Launch Pad
• Electron Beam® Launch Controller
• Recovery Wadding
• Igniters (w/ engines)
• Igniter Plugs (w/ engines)
• Recommended Estes®Engines: A8-3, B4-2,
B4-4, B6-2, B6-4, C6-3, C6-5.
HOLD KEY DOWN AND PRESS
LAUNCH BUTTON UNTIL LIFT-OFF!
4...
4...
4... 3... 2...1...
INSERT KEY.
PUSH DOWN
AND HOLD.
1...
1...
LAUNCH
BUTTON
3...
3...
4"(10 cm)
Masking
Tape
15 FT. (5 M)
2...
2...