Considering I have already flown this rocket for my L1 certification and was successful, I figure I should finish documenting the build before I send it up for my L2 cert. next weekend.
For the fillets I used wood epoxy and then topped it with 5 min. epoxy for a smooth finish.
This is the e-bay sled layout and assembly.
Here I have installed the rail buttons.
This image shows the construction of the ejection charge holders. The mounting hole is on the bottom, the hole that is drilled on an angle is for the electric match wires.
Here I have installed the ejection charge holders on the e-bay bulkheads.
This image shows the power terminals for the electric matches installed on the e-bay bulkheads.
Here the disconnect plug on the aft end of the e-bay has been installed.
I drilled small holes and used a thread tap to make threaded holes for the sheer pins in the nose.
This is a close up of the nylon sheer pins used in the nose cone/upper body connection.
I added weight to the nose to move the CG foward. After pouring lead shot and epoxy into the nose, I drilled four holes and inserted straight nails through the nose cone. I then added more epoxy. The nail heads will be ground down smooth with the surface of the nose cone.
I epoxyed a bulkhead with eye ring and shockcord attached into the nose cone and secured it with screws through the nose cone also.
The nails and screws were then ground down with a grinding wheel on a Dremel tool.
At this point I tested the ejection charges with all the parachutes and Nomex packed in the rocket and painted it. I will post a separate build article about how I made my ejection charges at a later time. They were easy to make and I found the idea on TRF.
Here is a picture on my son holding the rocket before we launched it for my L1 cert.