A Few Tips on Rocket Building

Preparation

Read the Instructions

Check that you have all the parts.

Understand the Rocket

Figure out how it fits together. Understand the types of forces that will act on each joint.

Have a Construction Plan.

Decide which types of epoxy (fast or slow, thickened or unthickened) will be used on each joint. Decide which pieces can be assembled in parallel, and which are order dependant. Figure out the critical path (the assemblage that will take the most steps to complete.) It will probably be the motor mount/ fin assembly.

Sand All Joints

Roughen all edges and surfaces that will be bonded. Do this for all parts before you even start to glue things together: it's easier to sand unassembled pieces. For TTW construction, don't forget to sand the outside of the motor tube and the inside of the fin can (where the fins will later be attached.) Wipe off all the dust.

Epoxying

Have a Plan

Plan each epoxy batch: what on the critical path will be assembled, what other parts will be glued with any left-over epoxy.

Pre-fit Everything

Check the fit of all components that are to be glued. Sand down overly tight parts, and fix overly loose parts by adding masking tape 'walls'

Use Masking Tape

Masking tape is great for holding pieces in place until the epoxy has cured. Also use it to keep epoxy where you want it: build dams around places that will be filleted; seal the reverse side of bulkheads to prevent drip-through; mask screw-threads to prevent stray drips from getting in the threads.