Estes Apollo 11 Saturn V Model Rocket Instructions

Marking the Tubes

1. Use a door frame as a guide to draw a straight line down the main and third stage body tubes.
2. Mark alignment lines on the main body tube at 3 inches (7.6 cm), 8 7/16 inches (21.4 cm), and 18 3/8 inches (46.7 cm) from the rear end.
3. Mark the alignment line for the front of the tube.

Assemble Engine Mount

1. Rough up the inside surface of the engine mount tube with sandpaper.
2. Apply glue to the inside surface and attach the engine mount tube assembly.
3. Attach the engine retainer with epoxy, following manufacturer's instructions, and let dry.
4. Apply glue to the marks made in step 1 and assemble the parts, letting them dry.

Install Engine Mount and Centering Rings

1. Slide the engine mount into the body tube until the rear ring is 3 3/8 inches (8.6 cm) from the rear end. Apply glue to the ring/tube joints and let dry.
2. Apply glue to the inside of the tube assembly at the rear and insert the reinforcing ring, leaving 3/4 inch (19 mm) of the tube assembly exposed. Let dry.
3. Carefully extend the alignment marks around the tube, ensuring the drawn rings are straight.

Install Third Stage Centering Rings

1. Apply glue to the bottom inside edge of the main body coupler.
2. Push the centering ring down into place using the end of a pencil.
3. Apply glue to the outside back edge of the third stage body tube.
4. Align holes and attach the centering rings.
5. Cut a 6-inch piece of aramid cord, thread it through the holes, and tie a double knot.
6. Glue the center from one of the laser-cut rings onto the bottom of the tube/coupler assembly.
7. Apply glue to the inside edge of the coupler and around the ring and tube joint. Let dry.

Install Third Stage Foundation Wrap

1. Carefully cut the third stage foundation wrap and glue tab. Curl the wrap, tape the ends together with low-tack tape, and glue the tab to the inside seam, leaving approximately 1/16 inch (2 mm) clearance at the top and bottom. Let dry.
2. Slide the wrap onto the coupler, draw a line around the body tube at the front of the wrap, remove it, apply glue to the tube at the mark, and slide the wrap back into place, aligning the seam with the tube's alignment line.

Assemble and Install Nozzles

1. Remove and trim nozzle halves and supply tubes from the sprue. Glue nozzle halves together and attach supply tubes using liquid plastic cement or CA glue. Ensure the middle portion of the tubes points down. Hold until set and check for straightness.
2. Paint the nozzle assemblies gun metal gray or silver and let dry.
3. Remove the bulkhead from its card, position it over the nozzles, and place plastic washers over the nozzle nubs. Use the spacer ring to press the bulkhead down evenly. Ensure washers do not interfere with the spacer ring fit.
4. Glue the washers in place with liquid plastic cement or CA glue and let dry.
5. Remove the spacer ring, apply yellow glue, and reposition on the bulkhead. (? Note: This step is for display purposes only; remove for flight).

Apply Tube Wraps

1. Orient wraps according to the diagram, marking the top of each for reference. Carefully remove vac-form wraps from excess plastic, cutting along corrugations on the left and leaving some excess on the right. Test fit and trim as needed. Use dimensions to cut the 1st stage wrap.
2. Lightly spray the 1st stage wrapper with spray adhesive, align its edge with the main body tube's alignment line, and apply it to the 3-inch (7.6 cm) ring.
3. Once dry, extend alignment lines along the sides of the tunnels on the inter tank and inter stage wraps for 11 inches (27.9 cm). Use these lines as guides to affix the wraps, ensuring tunnel locations align.
4. After the inter stage wrap is dry, extend 6-inch (15.2 cm) alignment lines from the sides of the forward tunnel to guide the application of the upper second stage wrap.
5. Apply the upper third stage wrapper to the third stage body tube and apply the body wrap reduction.

Assemble Fins

1. (Diagram shows applying glue to fin root edge and attaching to body tube).
2. ⏳ Let dry.
3. (Diagram shows X4 fins).

Prepare Fairings

1. Use a hobby knife to carefully remove fairings, leaving 1/16 inch (2 mm) of flash.
2. Use a hobby knife to carefully remove fairing bases and the alignment guide.
3. Use plastic cement to attach the fairing bases to the inside bottom of the fairings. ⏳ Let dry.
4. Use a hobby knife to carefully remove flashing from the fairings.
5. Remove fin slot indentations and bottom ledge from each fairing.
6. Test fit, trim, and sand each fairing to fit each fin and the lower first stage wrap.
7. Test fit fin and shroud at the shown location, using the card stock alignment guide for correct positioning.
8. Trim as needed for a perfect fit. (Diagram shows X4 fairings).

Attach Fins and Fairings

1. Apply plastic cement to the root edge of the fin. Use the shroud and card stock alignment guide for correct placement.
2. Hold in place until glue sets.
3. Remove the fairing and apply a glue fillet around the fin joint.
4. Apply plastic cement as indicated and replace the fairing.
5. When fins and fairings are dry, apply a reinforcing coating of liquid cement to the fin, fairing, and wrap joints. Let dry. Fill any holes with putty and sand flush. (Diagram shows X4 fins).
6. Once fairings are permanently affixed, cut away areas on the tube up to the reinforcing ring as shown.

Attach Plastic Tunnels

1. Mark and cut the half-round tunnels to connect between the 1st stage wrap and intertank wrap (both sides), between the intertank and second stage (both sides), and between the second stage and upper 2nd stage (one side). Use plastic cement to apply to the body tube.

Assemble Tower

1. (Diagrams show assembly of the tower structure using multiple parts and glue).
2. ⏳ Let dry.

Assemble Capsule

1. (Diagrams show attaching the tower structure to the capsule).
2. ⏳ Let dry.
3. ? Note: If planning to fly the Saturn V, consider not cementing the tower legs into the capsule holes to allow for removal before flight.
4. Insert four pieces of clay into the bottom of the capsule and press to secure.

Install Wire Anchor & Test Fit Nose Cone Assembly

1. Cut the template from the template sheet.
2. Use masking tape to secure the template.
3. Rotate back and forth to create a hole.
4. Bend brass wire to shape using the template.
5. ? Note: Do not glue at this time. Only test fit. Final assembly is after painting and checking center of gravity.
6. (Diagram shows attaching wire anchor).
7. ➡️ Align parts.
8. Insert four pieces of clay into the bottom of the capsule and press to secure.
9. ➡️ Align parts.
10. (Diagrams show further assembly steps for the nose cone section).
11. ➡️ Align parts.
12. Pull apart for painting preparation.

Install Launch Lugs

? Note: This step is only necessary for flight models.

1. Use plastic cement to glue the launch lugs over the alignment line on the main body tube, 1/4 inch (6 mm) below the second stage wrap and just above the first stage wrap. Let dry.

Install Shock Cord Mounts

1. Test fit the separate body sections and sand as necessary for a good fit.
2. Cut out the two shock cord mounts from card 083591 and fold them.
3. Lay the shock cord onto the mount at an angle, apply glue to section two, and fold section one over.
4. Apply glue to section three and fold forward again. Clamp until glue sets. Repeat for the other mount.
5. Apply glue to each mount and attach them to opposite sides of the main body tube, at least 2 inches (5.1 cm) down.
6. Tie a double knot at the free end of each shock cord.

Prepare Recovery System

1. Build all three parachutes according to instructions on their borders.
2. Form a loop in the shroud lines of one 24-inch (61 cm) parachute and lay a mounted shock cord over the loop.
3. Pass the parachute through the loop and pull tight. Repeat with the other 24-inch (61 cm) parachute.

Prepare Third Stage Recovery System

1. Form a loop with the shroud lines on the 18-inch (46 cm) parachute and tie the remaining shock cord to the loop with a double knot.
2. Tie the free end of the shock cord to the loop at the rear of the third stage.
3. Measure a 13-inch (33 cm) piece of aramid cord and tie one end to the snap swivel.
4. Tie the other end of the aramid cord to the shock cord, 15 inches (38 cm) from the rear of the third stage, then knot the shock cord over the aramid cord.
5. Snap the front of the snap swivel onto the brass anchor at the top of the LEM. (This allows detachment for packing or display). Unhook for painting.

Mask Model for Painting

This section details how to use templates and masking tape to achieve the correct paint scheme. It involves cutting templates, marking lines, and covering specific areas to ensure clean paint separation between colors like white, black, and silver.

1. Cut templates from the sheet.
2. Use masking tape to secure templates.
3. Make pencil marks around the template and at each line, extending them forward and back.
4. Use masking tape to cover areas that need to remain white.
5. Cut the template perimeter and inner gray areas with a hobby knife.
6. Align masks with features on the second stage wrap, wrap around the tube, and secure with tape.
7. Make pencil marks on both ends of the template on lines labeled "PENCIL LINE" and extend lines between them.
8. Use masking tape to cover areas that need to remain white.
9. Cut another template.
10. Wrap mask around fairings and secure with tape.
11. Make a pencil mark along the top of the template.
12. Remove mask and repeat for other fairings.
13. Make pencil marks at the top of the fairings and above the blow-molded feature between them, extending these marks forward.
14. Use masking tape to cover areas that need to remain white or silver.

Paint Rocket

This section provides detailed instructions for painting the model, including priming, base coats, masking, and applying specific colors to different sections of the rocket. It emphasizes using appropriate paints and techniques for a professional finish.

1. Remove the display nozzle assembly and paint the rear section silver or gunmetal gray. Apply a coat of sandable primer, let dry, and correct any flaws. Prime and sand until satisfied.
2. Spray the entire model with 3-4 coats of flat white paint and let dry for at least 24 hours. Study the diagram for paint pattern locations while the paint dries. Careful masking is crucial for the correct pattern.
3. Mask off fins and engine fairings and paint them silver or gun metal gray, matching the nozzle assembly color.
4. Cut out the masking guide for the Service Module (SM) and paint the exposed SM surfaces silver.
5. Paint the plastic RCS nozzles as shown in the diagrams.
6. Use the diagram to mask and paint the roll pattern.
7. Once the roll pattern is dry, use CA glue to apply the RCS nozzles.
8. Place the capsule on top of the LEM assembly, align the plastic tab with the seam and hook, make an alignment mark, and apply with CA glue.

Masking Notes: Use low-tack, flexible tape (automotive masking or pin-striping tape). For ordinary tape, reduce adhesion by pressing it onto glass. For compound curves, use narrow tape strips. Mask paint separation points carefully, cover large areas with paper or plastic, and tape edges down to prevent overspray. Mask coupler shoulders to prevent paint buildup. Spray a white coat to seal masked areas and minimize overspray. Once dry, spray the color. Remove masking while paint is still slightly tacky.

Apply Decals

1. Cut out one decal at a time, soak in warm water for 15-30 seconds until it slides easily from the backing paper. Transfer the decal to the model and gently blot away excess water and air bubbles with a soft cloth.
2. Align "USA", American flag, and "United States" decals vertically within paint patterns and horizontally between body wraps. Use light tic marks for orientation. Raised squares on the second stage and reduction wraps indicate locations for camera and target decals.
3. Finish by painting the entire model with a flat clear coat.

Prepare Flight Recovery

1. Crumple and place four squares of recovery wadding into the front of the engine mount tube.
2. Lay six squares of wadding flat in the bottom of the parachute compartment.
3. Spike, fold, and roll the 24-inch (61 cm) parachutes and insert them into the parachute compartment.
4. Lay two flat squares of wadding on top of the parachutes.
5. Fold and roll the forward section parachute, lay it on the wadding in the middle of the parachute compartment. Insert the forward section into the main body tube, twisting back and forth to ensure it doesn't bind. Sand if necessary.
6. ? Note: If needed, sand the inside edge of the body tube to smooth out any burs before inserting the nose cone.

Prepare Engine Retention

1. Wrap 6 to 8 layers of masking tape over the nozzle end of the motor, overlapping the end by 1/4 inch (6 mm).
2. Trim off excess tape.

Prepare Engine

1. (Diagrams show preparing the engine with starter and plug).
2. ⚠️ Warning: Flammable. Read instructions and NAR Safety Code. Prepare engine outside at the launch site. Remove starter before storing.

Check Center of Gravity for Stable Flight and Final Assembly

Ready for flight with Engine Installed

⚠️ Caution: Ensure the center of gravity (CG) is in the correct location for stable flight before the first launch. Check CG with an engine installed before proceeding.

? Note: Add weight to the nose cone until the correct CG is achieved.

? Note: Ensure display nozzles are not attached when checking CG.

1. (Diagram shows the assembled rocket with CG marked). The total length is 25.25 inches (64.2 cm).
2. ➡️ Align parts.
3. ➡️ Align parts.
4. ➡️ Align parts.
5. ➡️ Align parts.

Countdown and Launch

? Note: Key should remain out until final countdown.

1. Ensure the rocket is at least 8 inches (20.3 cm) above the blast deflector.
2. (Diagram shows connecting micro-clips to the engine igniter).
3. (Diagram shows inserting the launch key).
4. (Diagram shows extending the launch controller wire).
5. Ensure the launch controller wire is fully extended (30 ft / 9.1 m).
6. Insert key; the bulb will light.
7. Press the yellow button; an alarm will sound.
8. Press the red button while holding the yellow button to launch the rocket.

Precautions:

• Pre-Launch Check: Inspect rocket for damage (body, nose cone, fins, engine mount, recovery system, launch lug). Repair any damage.
• Flying Your Rocket: Choose a large field (500 ft [152 m] square) free of dry weeds and brown grass. Launch with little or no wind and good visibility. Always follow the National Association of Rocketry (NAR) Safety Code.
• Misfires: Remove the key from the controller. Wait one minute before approaching the rocket. Disconnect micro-clips, remove the engine, and take out the plug and starter. If the starter tip did not touch propellant, install a new starter ensuring contact. Push the plug in place and repeat launch steps.
• Launch Site Conditions: No dry grass or weeds.

Estes Launch Supplies Needed (Sold Separately):

• Porta-Pad® E Launch Pad
• Requires 1/4 in. Launch Rod
• Pro Series II™ Launch Controller
• Recovery Wadding
• Starters (with engines)
• Plugs (with engines)
• Estes® Engines: E16-4, F15-4

Estimated weight: 15.3 oz. (433.7 g)