Another thought here, the sabot sections must not melt when subjected to the exhaust gasses. Foam will melt unless sealed with something. How about using mat spray over the foam and then laying down a layer or two of aluminum foil? Or, what about making the sabot sections out of balsa? Or, gee I really like this one, making them out of shirt backing or tablet backing and coating them with epoxy? Remember, they are primarily spacers. The ring at the bottom will do the sealing.
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20 years ago