Cub Scout Pack 530 St. Charles, MO Boone Trails District Greater St.

Louis Area Council Bottle Rocket Launcher Plans

www.pack530.org
These launcher plans are the result of years of tweaking by different Scouters that has resulted in an inexpensive and easy to build design. There are more drawings here than are probably needed, but a good Scout is always prepared, and there should be enough information here that a Tiger Cub could take them into the hardware store and get what he needs to build a launcher. Building and launching water bottle rockets has become a tradition at our Packs Fall Campout. It makes a great first Pack project for new Tigers and the rest of the boys in the Pack look forward to it as well. It also gets them excited about building cars and participating in our Pinewood Derby. Its proven itself to be an extremely fun and educational project that can be done on the Den or the Pack level. There are only a few holes and slight modifications that need to be made to the otherwise stock parts in order to make the launcher. Look over the plans. If you think youll encounter difficulties making the modifications, ask around. Id be willing to bet theres a machinist or someone who knows a machinist in your Pack who could make the necessary modifications. Before you ask, decide how many you want to build. As a machinist myself I can tell you its easier to make four at one time than it is to make two now and two later. Our pack had one or two launchers when my son joined. Ive since made five more, and they use every one of them. Our Pack stays at around 80 boys + siblings, so this might give you an idea of how many launchers your Pack might want to build. The cost to build one of these launchers it estimated to be around $15. This should be well within most Packs budgets to build 2 or 3 of them. The Rockets themselves are made from two 1 or 2 liter soda bottles with three or more fins attached. I have included a basic drawing on how to make the rockets, but its pretty well left up to the Scouts imagination how he wants to make it. The only two real requirements with the rockets are fins and a little bit of weight placed in the nose of the rocket for stability. There are lots of web sites on the internet with information about water bottle rockets, so Im not going to go into too much detail. Do your homework and youll be able to make some really effective rockets. I hope you enjoy a new found hobby with water bottle rockets. Its brought a lot of joy to a lot of Scouts and siblings in our Pack and hope these plans help you in your endeavor. Y.I.S. Clay Beeler, CC Pack 530 *Note: If you print out these drawings, you might have to change your printer settings to get all of the details to print properly.

Rocket Launcher Parts List

Release Handle Assembly
Part # RH-001 RH-002 RH--003 QTY. 1 1 Material 3" X 1/2" Wood Dowel Rod or nice stick 8' X 3/16" Rope 7 1/16" X 1/8" Steel Rod

Launcher Base Assembly

Part # RL-001 RL-002 RL-003 RL-004 RL-005 RL-006 RL-007 RL-008 RL-009 RL-010 RL-011 RL-012 RL-013 RL-014 RL-015 QTY. 1 1 1 1 2 1 1 4 1 1 1 8 2 2 2 Material Solid 7/8" PVC 13/16" X 5/8" X 3/32" O-Ring 12" X 3/8" PEX Supply Tube 1/2" PVC Tee, S-S-S * 1/2" PVC Pipe 2" - 1 1/4" PVC Reducer 3" - 2" PVC Reducer 1/16" Sheet Metal or purchased brackets 5" X 12" X 1/2" Plywood ** 1/2" PVC Cap 1/2" NPT PVC Adapter #8 X 1/2" Sheetmetal Screws 3/8" Flat Washer 3/8" X 5 1/2" HHCS Bolt Made From RL-013, RL-014

Launcher Fill Tube Assembly

Part # FA-001 FA-002 FA-003 FA-004 FA-005 FA-006 FA-007 FA-008 FA-009 FA-010 QTY. 1 1 1 1 1 1 1 1 1 1 Material Tubeless Tire Valve Stem ** 1/2" PVC Cap * 1/2" PVC Pipe 1/2" PVC Elbow * 1/2" PVC Pipe 1/2" PVC Tee, S-S-F 1/2" NPT - 1/4" NPT Reducer PSI Preasure Gage w/ 1/4" NPT 1/2" PVC Pipe 1/2"NPT PVC Adapter

* NOTE: 1 - 10' Section of PVC Pipe will make all 1/2" PVC Pipe parts ** Note: 2- 1/2" PVC Caps Total *** Part FA-009 can be glued directly into part RL-004, thus eliminating one of the RL-005 parts and both RL-011 and FA-010. FA-009 can be shortened to make the entire assembly more compact.

Cub Scout Pack 530 St. Charles, MO Boone Trails District Greater St. Louis Area Council Bottle Rocket Launcher Assembly Instructions
www.pack530.org
These instructions should provide you with enough information to assemble your P-530 Rocket Launching System. Care should be taken to deburr all cuts made and to use primer on all of the glue joints. Follow the directions on the Primer and Glue cans. Make sure to wear safety glasses and follow all of the safety rules that you would with any other project. Dont hold PVC parts in your hands while drilling. Drills can have a tendency to grab in the soft plastic and you could wind up drilling your hand. If youre not sure about something, ask someone for help. Be safe. 1) Make the Launcher base according to the print provided. Painting this part with 2 coats of exterior house paint is recommended so that water doesnt damage the wood. 2) Cut all PVC parts per drawings. 3) Measure valve stem diameter where it fits into the valve stem cap. Determine the correct drill size and drill a hole in the center of the valve stem cap. Deburr the hole and insert the valve stem into cap. 4) Follow directions on the primer and glue cans and assemble all joints on the Filler Tube Assembly. Care should be taken to line up the Tee and the Elbow so that your Filler Tube Assembly is straight when finished. 5) Use Teflon tape and assemble the reducer into the threaded tee. 6) Use Teflon tape and assemble the pressure gage into the reducer. Your Filler Tube Assembly should now be complete. Allow the glue to dry according to directions on the glue can. 7) Use the drill templates provided in these drawings or use prefered method to drill holes in the Launcher Housing and Release Collar. Deburr all holes and chamfer the 4 holes in the Release Collar so the Release pin can be inserted easier. 8) Turn or sand Launch Tube according to print. *Note. The objective here is that tube above the sealing area becomes a slip fit through the opening of the bottle so the rocket has less friction on it when launching. This tube keeps the water from running down into the Filler Tube Assembly and keeps the water in the rocket where its needed. 9) Glue the Launch Tube into the Tee and carefully wipe off any excess glue around this joint. You dont want your O-ring spacer getting glued down when it comes time to adjust its length.

10) Assemble all parts of the Launcher Base Assembly according to the Launcher Base Assembly Detail drawing with the exclusion of the O-ring Spacer. *Note that the two mount tubes must be inserted through the Launcher Housing and then into the Tee. Remember to follow label directions and use primer and glue on all glue joints. 11) Attach the Launcher Base Assembly to the Launcher Base as per drawing using the 8- #8 X sheet metal screws. Drill pilot holes before inserting screws into the Launcher Housing. *Note the orientation of the threaded male adapter in relationship to the slots in the Launcher Base. 12) Make the O-ring spacer. Cut the spacer to length, and with a Dremel tool, open up the inside diameter to slip fit all of the way down the Launch Tube until it contacts the Tee. No glue is needed for the O-ring Spacer. *Note. Its better to cut it a little long than it is to start over. If your Release Pin holes in the Release Collar are a little off, this could effect the sealing efficiency of the o-ring. When you install the spacer, put the factory end up so the O-ring will have a good flat surface to rest on. See step #17 for more info. 13) Install O-ring. Slip o-ring over the Launch Tube and slide it down until it makes contact with the O-ring spacer. Your Launcher Base Assembly should now be complete. Allow the glue to dry according to directions on the glue can. 14) Make the Release Handle per drawing. 15) Make the Release Pin per drawing. *Note: If your pin is too wide to fit into the holes in the Release Collar you can narrow the distance between the forks by putting a curve in the section between the forks. If the release pin is too narrow, unbend it a little and try to make larger radius bends. The length of the forks is not very important as long as they protrude through the back side of the Release Collar when inserted into it. 16) Assemble the Release Handle, Rope, and Pin. Insert one end of the Release Rope through the hole in the handle. Tie a knot so the rope wont come back through the hole. Make a Larks Head knot around the Release Pin. I recommend putting an Overhand knot behind the Larks Head knot and wrapping the knots and pin with black electrical tape so that the pin doesnt come loose from the rope. Make a Lariat Loop knot in the remaining end and secure it to the rear facing Mount Tube between the cap and the Launcher Housing. Wrap this with tape so it doesnt come loose. This tether will keep the pin from possibly hitting and injuring the releasee when the Release Pin is pulled. 17) Insert a bottle over the Launch Tube and slide it down until it contacts the O-ring. Insert the Release Pin through the Release Collar. You should only have to apply SLIGHT down pressure on the bottle to get the Release Pin inserted. Too much pressure and youll force the O-ring out of position and it wont build up pressure. On the other hand, if theres no down pressure needed to insert the Release Pin it could leak as well. Work with the O-ring Spacer until you get a good seal. Once you have the length adjusted properly, its been proven to be a very reliable method of sealing the air and water in the bottle. 18) Last, youll need to tack weld the 3/8 washers on to the 3/8 bolts to make the Hold Down Pins. *Note: If you already have something that will serve to hold the launcher in place, you can probably skip #18. The length of the bolts is not critical, you just need long enough bolts to keep the launcher steady while the Release Pin is pulled. If you cant find long bolts, 3/8 rod with washers welded on the ends will also work. Leave about 3/16 clearance between the washers and the Launcher Base when the pins are driven into the ground. The slots are so you can turn the Launcher over, slide it into the bottle, then flip the entire thing back over so you dont loose water trying to get the bottle onto the launcher.

Congratulations! Youve built your very own P-530 Rocket Launching System.
Use at your own risk. This is a home made project and has not been engineered per say. Use it with adult supervision. Dont let anyone lean over the rockets while the rockets are pressurized. The rockets can launch with considerable force. Our Pack only allows 40 psi to be used to pressurize the rockets and weve never had an accident with pressurizing the bottles. You be your own judge on how much pressure to use and of how safe an activity this will be for you and your boys. When the rockets fall after reaching altitude there isnt much force, but we dont encourage letting the boys run after and try to catch them. The rockets can still hurt if they land nose first on their head, face or eyes. They can also trip while looking up and running to catch them. There is a lot if information on the internet about bottle rockets and launchers. A commonly recommended starting volume of water is 1/3 of the bottles volume. Encourage the boys to experiment with different ratios of water to air. A couple of web sites also show how to build a parachute for your rocket and how it deploys. Water Bottle Rockets are used in schools and universities as teaching aids and by people as a hobby. Used properly and with safety in mind, water bottle rocketry can be a safe and enjoyable hobby. Have Fun!