The construction of this rocket was a nonlinear process. Many parts can be worked on concurrently. When it all comes together it is quite satisfying.
The pods are constructed by centering an 18mm tube inside a shorter 24mm tube. I made sure the aft centering ring was flush. I also added a ring inside the aft end of each 18mm tube to strengthen them, since they will be hitting the ground first.
I cut the fins from 1/8inch hard balsa. This balsa is very tough and a bandsaw really helps to cut them close. A stationary sander finished them off.
The two sets of fins had to have exactly the same span, and exactly parallel edges, otherwise they won’t meet up on the edge of the pod. This took some care. It also helped to have through-the-wall attachment of the fins to the pods.
I first attached all three forward fins, then each rear fin and pod together.
The motor mount is a standard 24mm long Estes mount, for black powder E motors. It will also take 24mm reloads.
I chose to depart a little from the 3D model and put a bunch of tapered ribs at the aft end rather than try to fit the fins into a tapered shroud. I think it adds interest and looks cool.
I added the curved detail at the root of the forward fins as a separate piece
I filled any crevices with Elmer’s wood filler, and gave it one coat of white Kilz. Then I gave it one coat of grey primer to hide any color differences that might show through the red.
The final color is two coats of gloss red enamel (Ace Hardware). The white is spray enamel on the pod nose cones, hand painted on the large nose cone, and is actually a vinyl sticker on the main body tube.