I picked up an Estes Big Daddy today with the 40% off coupon from Hobby Lobby and just spent an enjoyable late evening setting up the motor mount.
However, their directions miss a few opportunities to be better. I've built several Estes rockets over the years and now my Sons are just getting into it, I like to follow the directions and look ahead for potential problems and areas to easily modify for improvement.
It turns out the yellow spacer tube in our kit was either too short or there is a misprint as to where to mark the motor tube. As pictured the motor block ring meets the motor hook but if you follow the spacing and marking procedure you'll end up with those two items about 3/16" too far apart.
Fortunately I realized this before the glue dried and I set up the ring to the correct spacing, while I was at it, I trimmed the motor hook on the drive end in case I ever decide to try a reloadable casing.
One tip I'll pass along- the disc of scrap from the upper motor mount makes a nice doubler for the former where the shock cord passes through. I placed it on the top side where it wouldn't interfere with the fin interface. I also used a section of Kevlar tied to a 1/4 x
9/16" multi-layered ply instead of a lower shock cord, and passed it through the upper motor mount. It's glued in forming the bottom of the sandwich that is ply / former / disc scrap.Since the fins are laser cut they are very accurate however an opportunity is missed since the instructions don't mention checking the spacing of the two motor mount rings as the rings are being glued in. Once the rings are on the motor tube, I used a fin to space them exactly, then applied the glue fillets to the mounts. The alternative is to roll the dice and hope the motor mounting rings aren't too far apart, or spend time sanding across the grain to shorten them up to fit between rings that are too close.
Now when the motor mount assembly is slid into the body tube, the fins will meet up with the motor tube and upper and lower motor mount rings perfectly. I'll then attach the shock cord to the Kevlar keeping enough space so the Kevlar is taking most of the heat.
Hopefully this will be useful to someone else building this kit someday.
Mike Doyle