Estes 2109 User Manual

COUNTDOWN AND LAUNCH

8" (20 cm)

KEY ALWAYS OUT UNTIL FINAL COUNTDOWN!

2...

3...

LAUNCH SUPPLIES (Sold Separately)

• Porta Pad® II Launch Pad

• Electron Beam® Launch Controller

• Recovery Wadding

• Igniters (with Engines)

• Igniter Plugs (with Engines)

• Recommended Estes® Engines: Single Stage A8-3, B4-4, B6-4, C6-5

• Two Stage Flights: Booster Stage - B6-0, C6-0,

• Upper Stage - A8-5, B6-4, B6-6, C6-5, C6-7

www.estesrockets.com

ESTES INDUSTRIES

1295 H Street

Penrose, CO 81240

PRINTED IN CHINA

FLYING MODEL ROCKET KIT INSTRUCTIONS

KEEP FOR FUTURE REFERENCE.

EST 2109

ASSEMBLY TIP: Read all

instructions before beginning work on your model. Make sure you have all parts and supplies.

TEST-FIT ALL PARTS TOGETHER BEFORE APPLYING ANY GLUE!

If any parts don’t fit properly, sand as required for precision assembly.

1...

Masking Tape

LAUNCH BUTTON

15 FT. (5 M)

4...

5...

4... 3... 2... 1...

HOLD KEY DOWN AND PRESS LAUNCH BUTTON UNTIL

LIFT-OFF!

INSERT KEY. PUSH DOWN AND HOLD.

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.

BT-60

BT-50

Body Tube

(1) 18” (45.7 cm)

(30401)

Die Cut Balsa Fins (1) (32212)

Die Cut Balsa Fins (1) (32213)

BT-5 Body Tube

(2) .75” (19 mm)

Upper Stage

Booster Stage

A8-5, B6-4, B6-6, C6-5, C6-7

B6-0, C6-0

Single Stage A8-3, B6-4, B6-4, C6-5

(30409)

Tube Coupler JT-60 (Red)

(1) (30176-5)

Centering Ring Cards (2)

RA 2060 (30128)

Body Tubes (2)

5” (12.7 cm)

(30415)

Adapter Rings (2)

RA-2050 (Green)

(30164-2)

Booster Stage Body Tube

Clay Weight (1)

(85704)

BT-20

Engine Mount Tubes

(2) 2.75” (7 cm)

(30408)

BT-60

(1) 3.25” (8.25 cm)

(30404)

Shock Cord (1)

1/4" x 24"

(38383)

Launch Lug (1)

1/8” x 2 3/8”

(38178)

Die Cut Disc Card

(1) (37172)

Plastic Nose Cone (1)

PNC-60CP (60541)

Plastic Nose Cones (2)

PNC-50KA (71028)

Plastic Nose Cones (4)

PNC-5A (72600)

HELPFUL HINT: IF NOSE CONE/COUPLER FIT IS. . .

TOO LOOSE

TOO TIGHT

PRECAUTIONS

NAR Safety Code

NO DRY GRASS OR WEEDS

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! Disconnect the igniter clips and

remove the engine. 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.

P/N 60538 (07/03)page 8

Decal Sheet (1) (60549)

SUPPLIES

SCISSORS PENCIL

In addition to the parts included in the kit you will also need:

RULER

FINE

SAND PAPER

(#400-600 GRIT)

PN 60549 (5-03)

CARPENTER’S

GLUE

Adapter Rings (2)

RA-520 (Green)

(30162-2)

MODELING

KNIFE

PLASTIC CEMENT

Assembled 12” (30 cm)

Parachute

(1) (35801)

MASKING

TAPE

SPRAY

PRIMER:

WHITE

SPRAY PAINT:

BLACK,

COPPER

ADD MASKING TAPE.

SPRAY CLEAR

COAT

SAND FOR FIT.

CELLOPHANE

TA PE

11. UPPER STAGE STAGE ENGINE MOUNT INSTALLATION

120˚

PARTS

ENGINE MOUNT ASSEMBLY

FRONT

A. Use finger to smear glue 2” (51 mm)

inside upper stage body tube.

UPPER BODY TUBE

2”

(51 mm)

REAR

BODY TUBE

GLUE

ENDS FLUSH

B. Insert engine mount until flush with end.

Let dry.

SCRAP BALSA

C. Use a scrap piece of balsa to apply a glue fillet between

the centering ring and body tube joint. Let dry.

3. BOOSTER STAGE ENGINE MOUNT ASSEMBLY

PARTS

ENGINE MOUNT TUBE

BT-20

ADAPTER RING RA-520 GREEN

DIE CUT CENTERING RINGS

FRONT

A. Carefully remove centering

rings from card using a modeling knife.

FRONT

1/8”

(3 mm)

2 1/2”

(64 mm)

B. Mark tube at the 1/8” (3 mm) mark

and 2 1/2” (64 mm) mark from end.

FRONT

12. ATTACH UPPER STAGE FINS

PARTS

FINS

B. Repeat for

A. Apply thin layer of glue to lower

fin, wait 1 minute. Apply 2nd thin

UPPER BODY

TUBE ASSEMBLY

layer and attach fin centered on fin line even with end of body tube.

Let dry

NOTE: FINS MUST BE ATTACHED

CORRECTLY FOR A STABLE FLIGHT.

13. ATTACH LAUNCH LUG AND APPLY GLUE FILLETS

PARTS

LAUNCH LUG

4 1/4”

(108 mm)

A. Mark Launch lug line at 4 1/4” (108 mm).

Glue launch lug centered on “LL” line even with mark. Let dry.

14. INSTALL NOSE WEIGHT

PARTS

remaining fins. Let dry.

END VIEW

B. Apply glue fillets to all

fin and launch lug/body tube joints. Let dry.

C. Stand rocket on

flat table until glue dries completely.

FLUSH

C. Apply a ring of glue just inside the

end of the tube, insert the adapter ring until flush with end. Let dry.

PARTS

FLUSH

BT-60

BOOSTER STAGE

BODY TUBE.

PARTS

(19 mm)

RED TUBE COUPLER

H. Mark red tube coupler

at 3/4” (19 mm).

4. PREPARE BOOSTER TUBES

PARTS

NOSE CONE (2) PNC-50KA

1/8”

(3 mm)

2 1/2”

(64 mm)

D. Push the centering rings onto the tube,

at 1/8” (3 mm) and 2 1/2” (64 mm) marks.

F. Insert engine mount until the

motor tube is flush with the end.

3/4”

I. Apply a ring of glue inside the

front of booster tube at the body tube/centering ring joint.

E. Apply glue fillets to both

sides of each ring. Let dry.

G. Apply a glue fillet to the inside

ring/body tube joint. Let dry.

J. Insert red adapter into booster

tube up to the 3/4” (19 mm) mark. Let dry.

FRONT

FLUSH

FRONT

3/4”

(19 mm)

COMPLETED ASSEMBLY

FRONT

CLAY WEIGHT

NOSE CONE

15. INSTALL SHOCK CORD MOUNT

IO T C

E S

A. Cut out shock cord

mount from top of page 2.

page 6

IO T C

E S

B. Apply glue.

fold foreward.

SHOCK CORD

A. Form the c lay weight

into a thin snake.

C. Apply glue.

Fold forward.

D. Squeeze tightly

and hold for one

minute

CLAY

B. Use a long wooden pencil to

tamp the clay into the front of the nose cone as far as possible.

Use all of the clay.

1”

(25 mm)

E. Glue mount 1” (25 mm) inside upper stage

body tube. Hold until glue sets. Let dry.

GREEN ADAPTER RINGS (2) RA-2050

BODY TUBE (2) BT-50

DISCS (2)

A. Remove flash from

nose cones using a modeling knife.

T N

TIC

E S A

D. Apply a ring of cement inside front of

body tubes. Insert nose cone. Let dry. Repeat for 2nd tube. Let dry

B. Apply a ring of glue

just inside end of tube.

Insert adapter ring

flush with end. Let dry.

C. Repeat for 2nd

tube. Let dry.

COMPLETED BOOSTER TUBE ASSEMBLY.

E. Apply glue to end of tube and press disc in

place. Let dry. Repeat for 2nd tube. Let dry.

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