Saturn 1B SA-206 Model Rocket Instructions

Keep for future reference.

IMPORTANT: Please record date found on decal and keep for future reference.

Read all instructions. Make sure you have all parts and supplies. Test fit all parts before applying glue.

Historical Context

The Estes scale model SA-206 represents the Saturn 1B, a powerful rocket developed by NASA. It played a crucial role in the Space Age, particularly in test flights for the Apollo program and missions to the Skylab Space Station. The SA-206 specifically models the rocket that launched a crewed command service module to Skylab on May 25, 1973.

The Saturn 1B was a workhorse rocket, with 14 units constructed. It was used in numerous test flights, including the AS-201 mission which tested the Saturn 1B and Apollo Command and Service Modules. Five of the 14 Saturn 1Bs were flown with astronauts aboard.

Required Supplies

• Sandpaper: #220, #320, #400, and #600 grit
• Pencil
• Tweezers
• Hobby knife with several sharp blades
• Yellow glue
• Tube-type plastic cement
• Liquid plastic cement
• Permanent spray adhesive (not artist's or repositionable)
• CA (Cyanoacrylate) adhesive
• CA Accelerator (for plastics)
• Sanding Sealer (or sandable auto primer)
• Putty for plastic models
• Masking tape
• Small paint brush
• Paints: Flat Black, Flat White, Silver

Note on Adhesives and Paints: Be extremely careful when using cyanoacrylate adhesive (CA). Avoid contact with eyes and skin; safety glasses are recommended. Ensure adequate ventilation when using adhesives and paints. Do not use lacquer-based paints, as they can melt the plastic parts.

General Assembly Tips

Working with Vac-Formed Parts

Vac-formed parts require patience. To cut them, apply light pressure and make repeated passes with a sharp blade along the desired cut line. Avoid excessive pressure, which can cause the blade to move and result in an uneven cut.

After cutting, sand the edges to remove flash and create a smooth bonding surface. Use sandpaper (#220 or #320 grit) on a flat surface. Wet-or-dry sandpaper can be used with a little water to prevent clogging. Sand parts in a circular motion with even pressure to avoid uneven edges. Be cautious with thin edges to prevent removing too much plastic or generating heat that could warp the part.

Double-sided tape can be useful for holding small parts. Files can be used to remove excess plastic from parts that are difficult to hold.

Adhesives for Vac-Formed Parts

Vac-formed parts are thinner than injection-molded parts, requiring specific adhesives. Liquid plastic cement (e.g., Plastic Weld Cement, Testor's Plastic Cement, Tenax 7R, glue pens) chemically welds styrene by dissolving the plastic. Apply with an artist's brush, allowing the liquid to flow into close-fitting parts and then squeezing them together.

Super glue (cyanoacrylate) is also recommended. Use a toothpick or pipette to apply CA accelerator one drop at a time, as spray applicators can soften and stain plastic surfaces.

Filling Seams

Seams are common in vac-formed models and need filling. Recommended putties include 3M Acryl-Blue or Squadron Green or White Putty. Use putty sparingly to avoid extra sanding and potential "sinkholes" (where the putty collapses the plastic). Masking tape along seams can minimize excess putty. Build up low areas with multiple thin layers rather than one thick layer to reduce shrinkage and cracking. Allow putty to dry overnight before sanding. Wet-or-dry sandpaper (#220 grit up to #600 for polishing) is recommended.

Parts List

The kit includes various components for assembly. Key parts include:

• Body Tubes: Core body tube, second stage body tube, LEM body tube, aft body tube, nozzle spacer tube, fuel body tubes (x8)
• Wraps: Upper body wrap, interstage wrap, lower body wrap
• Engine Components: Green engine block, engine mount tube, E engine hook, engine spacer tube
• Fins: Outer engines (x4), inner engines (x4), injection molded fins (x8)
• Other Components: Wire, clay (x4), snap swivel, centering rings, tunnels and antenna, launch lugs, tank shroud, escape motor body, plastic parts set, laser cut card stock, waterslide decal sheet
• Recovery System: Shroud line, 18" (45.7 cm) shock cord, 42" (107 cm) shock cord, 18" (16 cm) parachute, 15" (38 cm) parachute

Assembly Instructions

Assemble Engine Mount

Step 1: Trim a slot in the core tube between any two of the outer eight fuel body tubes. The slot should be 1/8 inch (3 mm) wide.

Step 2: Apply glue inside the tube at the locations where the slot was made.

Step 3: Align the engine clip with the notch. The clip should be positioned 1 inch (25 mm) from the top of the engine mount tube.

Step 4: Ensure the ends are even. Let dry.

Assemble Aft Body Section

Step 1: Trim the bottom edge of the raised detail on the aft body tube section by 1/32 inch (0.8 mm).

Step 2: Trim the left and right areas of the wrap to approximately 3/16 inch (5 mm). Wrap the trimmed section around the aft body tube, ensuring the ends meet cleanly. Apply several light coats of spray adhesive to the tube, then apply the wrap.

Step 3: Sand the top edge smooth using sandpaper on a flat surface.

Step 4: Align the tank shroud to the center line of the body tube. Extend the center line upwards. Measure and mark the center.

Step 5: Attach the tank shroud to the top of the body. Be mindful of sharp points on the shroud.

Step 6: Align the tank shroud to the center line of the body tube. Extend the center line up. Measure and mark the center.

Step 7: Remove excess glue.

Attach Fins

Step 1: Remove the laser cut ring and the fin alignment jig from the ring.

Step 2: Remove the fin alignment jig from the ring.

Step 3: Apply glue to the top of the paper template found on the Saturn 1B templates page.

Step 4: Center the laser cut ring over the printed template.

Step 5: Apply plastic cement to the fins.

Step 6: Use the jig to align the fins until dry.

Step 7: Place the assembly over the paper template to align all 8 fins. Let dry. (Repeat for all 8 fins, indicated by X8).

Apply Upper Body Wraps

Step 1: Trim the top and bottom edges of the raised detail away by 1/32 inch (0.8 mm).

Step 2: Extend a pencil line along the entire length of the body tube.

Step 3: Apply several light coats of spray adhesive to the body tube, then apply the wrap.

Step 4: Apply several light coats of spray adhesive to the body tube, then apply the wrap.

Step 5: Attach tunnels with plastic cement. Let dry.

Assemble Fuel Body Tubes

Step 1: Attach the core body tube to the laser cut centering ring using yellow glue.

Step 2: Allow to dry on a flat surface.

Step 3: Lay the core body tube on a flat surface with the centering ring hanging off the edge. Apply glue along the entire length of a fuel body tube and roll it onto the core tube. Apply glue along the entire length of the tube.

Step 4: Let dry.

Step 5: Place a second fuel body tube in place using the same gluing application. Let dry.

Step 6: Add the next three tubes, applying glue as before and allowing each to dry.

Step 7: Once dry, remove from the flat surface and add the remaining fuel body tubes. Apply glue fillets between all eight tubes. Ensure no glue is applied to the outer surface.

Install Engine Mount

Step 1: Cut a slot in the core tube between any two of the outer eight fuel body tubes.

Step 2: Apply glue inside the tube at the locations where the slot was made.

Step 3: Align the engine clip with the notch. The clip should be positioned 1 inch (25 mm) from the top of the engine mount tube.

Step 4: Ensure the ends are even. Let dry.

Assemble Lower Body Section

Step 1: Apply plastic cement at the base of the core.

Step 2: Slide the assembly to the base of the core.

Step 3: Apply glue fillets as indicated. Let dry.

Attach Upper Body Centering Rings

Step 1: Apply glue inside the body tube at the two indicated locations.

Step 2: Mark the lower body section 1/4 inch (6 mm) below the centering ring.

Step 3: Let dry.

Attach Upper Body

Step 1: Apply glue inside the body tube at the two indicated locations.

Step 2: Mark the lower body section 1/4 inch (6 mm) below the centering ring.

Step 3: Slide the body tube through the glue and down to the mark made in Step 2.

Step 4: Align the upper wrap as shown between any two tubes.

Assemble Tower

Step 1: Connect the tower components as shown.

Step 2: Apply glue to the tower legs and the base.

Step 3: Insert the tower legs into the corresponding holes in the base.

Step 4: Ensure the tower is straight before cement dries. Let dry.

Note: For flight, you may choose not to permanently cement the tower legs into the capsule base. This allows for removal of the fragile tower before flight.

Assemble Capsule

Step 1: Prepare the capsule components.

Step 2: Apply glue to the capsule base and the tower connection points.

Step 3: Glue the capsule base into the bottom of the capsule. Set the capsule on a flat surface, drop liquid plastic cement into the tower leg holes, and insert the tower. Ensure the tower remains straight while the cement dries.

Step 4: Let dry.

Install Wire Anchor

Step 1: Cut out the wire anchor from the Saturn 1B Templates page.

Step 2: Use masking tape to secure the anchor to the body tube.

Step 3: Cut a slit for the wire anchor. Rotate back and forth to create a hole at the four RCS locations.

Step 4: Remove the template after the holes are made in the body tube.

Step 5: Prepare the wire anchor components.

Step 6: Attach the wire anchor using scrap paper for support.

Step 7: Attach the wire anchor components.

Step 8: Let dry. Note: Do not permanently glue in place until the final balance of the model is performed. See page 11 for the Center of Gravity balance point.

Attach Launch Lugs and Detail Parts

Step 1: Identify the positions (POS 1, POS 2, POS 3, POS 4) for the launch lugs and detail parts on the body sections.

Step 2: Confirm launch lug alignment.

Step 3: Attach the launch lugs and detail parts according to the indicated positions. Let dry.

Assemble Display Engines

Step 1: Center and glue two rings and the tube as indicated.

Step 2: Prepare the outer and inner engines.

Step 3: Glue the outer engines to the mount with plastic cement. (Repeat x4)

Step 4: Repeat the process for the inner engines. Let dry.

Paint Rocket

Before painting, ensure all parts are firmly attached and any small gaps are filled. If spirals in body tubes were not filled, do so now. Spray adhesive can be removed with a tissue dipped in enamel thinner. Wood glue or CA can be removed with fine-grain sandpaper.

For masking, you can spray the entire model white and then use bottle paint for black and silver areas. Again, do not use lacquer-based paints, as they will damage the plastic. Test paints on scrap plastic if unsure.

Painting Scheme: Apply white paint to the upper sections, silver to the lower fins and accents, and black to the RCS nozzles and lower body sections. Specific dimensions for paint lines are provided on the diagram (e.g., 15/16" (24 mm) for black/white line, 17/32" (13 mm) for silver/black lines).

Balancing: Add additional weight to the nose cone area if needed to balance the model. The center of gravity for flight is indicated on the diagram.

Apply Decals

Step 1: Cut out decals one at a time. Soak them in warm water for 15-30 seconds until the decal 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.

Step 2: Center the "USA" and "United States" decals vertically within the paint patterns and horizontally between body wraps. Use light pencil marks for proper orientation. Raised squares on the second stage and reduction wraps indicate locations for camera and target decals.

Step 3: Finish by painting the entire model with a flat clear coat.

Attach Shock Cord

Step 1: Cut out the shock cord mount on the Saturn 1B Templates page.

Step 2: Prepare the shock cord mount components.

Step 3: Prepare the shock cord mount components.

Step 4: Hold until set.

Step 5: Apply glue to the shock cord mount.

Step 6: Glue the mount to the inside of the main body tube. The mount should be positioned approximately 2 inches (5 cm) from the end.

Step 7: Use a finger to hold until glue sets. Let dry.

Prepare Recovery System

Step 1: Form a loop in the shroud lines of the 18" (45.7 cm) parachute.

Step 2: Lay the knotted end of the shock cord over the loop.

Step 3: Pass the parachute through the loop and pull tight.

Prepare Upper Stage Recovery System

Step 1: Form a loop with the shroud lines on the 15" (38.1 cm) parachute, and tie the remaining shock cord to the loop with a double knot.

Step 2: Tie the free end of the shock cord to the loop at the rear of the LEM shroud.

Step 3: Measure a 13" (33 cm) piece from the shroud line material and tie one end to the snap swivel.

Step 4: Tie the other end of the line to the shock cord, 15" (38.1 cm) from the rear of the third stage, then knot the shock cord over the line.

Step 5: Snap the front of the snap swivel onto the wire anchor at the top of the LEM. The snap swivel allows detachment of this portion for display. Unhook for painting.

Prepare Flight Recovery

Step 1: Crumple and place four squares of recovery wadding into the front of the engine mount tube.

Step 2: Push four squares of recovery wadding into the bottom of the parachute compartment.

Step 3: Spike, fold, and roll the 18" (45.7 cm) parachute and insert it into the parachute compartment.

Step 4: Lay two squares of recovery wadding on top of the parachute.

Step 5: Attach the snap swivel to the wire anchor. Spike, fold, and roll the 15" (38.1 cm) parachute, and 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 the sections do not bind.

Prepare Engine

Step 1: Locate the engine.

Step 2: Use one starter and one plug.

Step 3: Ensure the tip of the starter just touches the propellant.

Step 4: Spike, fold, and roll the engine components.

Step 5: Prepare the engine for launch. Note: To avoid serious injury, read instructions and the NAR Safety Code included with engines. Prepare your engine only when outside at the launch site. If the prepared engine is not used, remove the starter before storing the engine.

Estes Fleet of Scale Kits

Estes offers a variety of scale model rocket kits. Featured models include:

• 2056 U.S. Army Patriot M-104
• 3228 V2
• 1293 Black Brant III
• 1921 Mercury Redstone 4 Liberty Bell 7
• 7000 Bull Pup 12-D
• 7255 Little Joe I
• 9720 Doorknob
• 2446 Mini Honest John

Visit EstesRockets.com to see the entire fleet. Note: Rockets shown are not to scale with each other.

The marks ESTES®, the Estes® rocket logo, and Porta-Pad® are marks of Estes Industries, LLC registered in the U.S. and other countries. All other product names and marks are the property of their respective owners.