Build Thread: Estes Dark Star #2045
 

It's time to clone a scarce one.

It's time for......DUN, dun, DUUUUUUN....... "Operation Dark Star"!!

I've only seen images of the catalog page for this 4FNC. I've never seen the actual model or the kit. It seems it appeared only in the Estes 1991 catalog and then disappeared like a poot in a wind tunnel.

I've finally collected all of the components I need--with an accurate fin pattern being the last needed item. I have vinyl decals from Stickershock but I also have a roll of very glittery vinyl adhesive film that I might use for the 3" band forward of the fins.

I'll slit the (4) fins from my last sheet of 1/8" Midwest basswood. The PNC-60/nozzle combo is a loose one I've had laying around for years. I'll extend the engine mount tube to 6" and modernize it a little with a mylar engine hook ring, Kevlar shock cord leader, and a 48" long shock cord of 1/4" elastic fabric.

The catalog photo shows the model with plain black fins but I've also seen images of the model with gold triangular patterns on the fins. With the model lasting only one production year, I'm not sure how this variant happened--unless it was just a builder's random capriciousness that went public.

...and away we go!

TBC

First I'll knock out the fins.

It took (2) #11 blades to do it but I slit the (4) fin blanks from the rock-hard, bone-dry basswood. I then laid the Corian slab covered with 120 grit across my Herculean thighs and scraped the blanks to match each other and rounded the leading edges.

TBC

I built one last July. It did not have the triangle decals; just the big gold speckled panel, two gold stripes, and the "Dark Star".

I hate to admit this, but I do have a second one still in the bag........

That's pretty! Are those decals original?

Yep! I can't remember too well but I think the gold panel and stripes were self stick.

I did paint the nozzle unattached so that I did not have to do a massive masking job.

Next I mark the 18" long BT60 for (4) fins and (1) launch lug. For the launch lug line I bisect (2) of the fin lines and draw it on the mark.

I then mount (2) of the fins and since I've not yet inserted the engine mount to cause a protrusion I can use my "patented", imbecile-proof, even numbered only, swept fin alignment system. I then repeat with the other (2) fins.

I then glue the launch lug on it's line and register it with a piece of 1/2" x 1/2" angle aluminum.

Lastly, I fillet the fins and launch lug with epoxy. The fins are in perfect alignment.

TBC

Next I assemble the engine mount and epoxy a Kevlar shock cord leader to it. I then epoxy the engine mount into the main BT......and voila! The Dark Star is ready for finishing. I'll paint the rear nozzle and the rest of the model separately and then glue the nozzle into place.

TBC

Wow, that is a neat trick for keeping opposite side fins in perfect alignment. I am going to have to try that on my next even numbered fin build.

It works so well it should be illegal.

Almost done.

The fins have (4) coats of sanding sealer and the model has been shot with (2) coats of black primer and (2) coats of gloss black enamel. "The Vixen" hand painted the plastic nozzle with Model Master metallic gold enamel (my last jar of it. :( )

Now for the Stickershock vinyl decals!

TBC