Made In USAKit #05051 Skill Level 3

Skill Level 3Average Skills NeededThe Zephyr Jr. is designed as a reduced-size scale

model of the Zephyr rocket. Since the Zephyr is such a popular rocket, we wanted to make a version that is a little smaller, meaning it will be easier to build, transport and fly. And it still retains the shape that makes the Zephyr rocket the pride of any rocketeer’s collection.

The rocket is built around a 24mm diameter motor mount, so it can be launched with a wide variety of mo-tors. We recommend starting out with a D or a small E size rocket motor for the first flight, because this is a light-weight rocket that has unexpectedly high performance. It is also easy to build, thanks to its laser-cut components and simple parts.

Zephyr Jr. Parts List

Needed Tools and Materials � Pencil � Ruler with a straight edge � Scissors � Hobby Knife with Sharp Blades � Wood Glue � Super Glue (CyA adhesive – medium viscosity) � Aluminum "Angle" to draw lines on the tube � Masking Tape

Optional Tools / Finishing Supplies � Masking Tape � Paper Towels � Bowl of water with a little dishwashing soap � Paint Supplies: Spray Paint, Brushes, etc � Sandpaper 220 grit, 400 grit and Sanding Block

Sheet A - P/N 31042

Manufactured in the USA by:Apogee Components Inc.

Colorado Springs, Colorado, USAVisit us online at:

www.ApogeeRockets.com

Item # Item Name Qty10091 AT-24/3.75" 110160 AT-56/18" (BT-70) 113035 CR-24/29 113056 1/4" Launch Lug 3" Long 115025 CR-24/56 Cardstock (Rectangle) 115539 Zephyr Jr. Fin Sheet Basswood 119470 PNC - 56mm (BT-70) 129123 32" Parachute Pack for Kits 129520 300# Kevlar x 8 Feet 131042 Zephyr Jr. Instruction Sheet A 131043 Zephyr Jr. Instruction Sheet B 135576 24mm Display Stand Cardstock LC 139041 Zephyr Jr. Face Card 141095 Zephyr Jr. Decal 147133 Clear Plastic Gusseted Bag 10x6x24x2mil 1

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Step 4

Assembly StepsAssembly Steps � 1. Carefully remove all the pieces from the fin sheet

by freeing the edges with a sharp hobby knife. Do not sand the edges of the fins until after assembling them in the next step.

� 2. Assemble the three fins by gluing the edges together as shown using wood glue.

� 3. Sand it with 400 grit sandpaper with a sanding block or Apogee’s Sanding Tee. Repeat the procedure until the balsa grain is filled and the fins look and feel smooth.

� 4. Cut a notch out of the green CR-24/29 reinforce-ment ring and one of the cardstock centering rings. This will be used as a pass through for the shock cord.

� 5. Make a mark 0.5 inches (12.7mm) from each end of the motor mount tube. Put a ring of wood glue around the tube at one of the marks and slide the un-notched card stock centering ring onto the tube to glue it in place. For reference, this will be the aft (rear) end of the motor mount assembly.

� 6. Tie a loop in the shock cord with the diameter just bigger than the motor mount tube and slip it over the forward end of the tube.

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Step 1 Step 2

RearStep 5

Step 6

Step 3

Overlap

Fin

Fin

Fin

Launch Lug

Zephyr Jr. Tube Marking Guide

0.5"12.7mm

0.5"12.7mm

Step 14 - Optional

Step 8

7”

Step 12

Step 10

Step 13

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Step 11 Yes No

Step 9

Fin

Fin

Step 7

� 7. Threading the end of the yellow shock cord through the notch, put a ring of wood glue at the forward mark. Then position the forward cardstock centering ring at the forward mark to glue it in place.

� 8. Threading the end of the shock cord through the green centering ring, put a ring of wood glue right in front of the forward centering ring and slide the green centering ring on the tube, up against the cardstock centering ring.

� 9. Cut out the tube marking guide. Wrap it around one end of the large body tube, and tape it so it doesn’t slide around. Mark the tube at each location, and label where the three fins and launch lug will attach, then extend those lines along half the length of the tube using an aluminum angle.

� 10. Temporarily pass the shock cord out through the motor mount tube so it is out of the way. Then slide the engine mount into the larger body tube and glue in place with wood glue such that the aft edge of the motor tube is flush with the bottom of the body tube.

� 11. Using wood glue, attach the fins to the rocket with the aft-most edge of the fin that still makes contact with the body being 0.25 inches (6.3mm) from the aft edge of the body tube. Make sure the fins are perpen-dicular to the tube. Allow the glue some time to dry.

� 12. Using wood glue, attach the launch lug to the rocket with the aft-most edge of the lug at 7” (17.7cm) from the back edge of the body tube. Make sure that the launch lug is straight along the tube.

� 13. Put a wood glue fillet along the edges of all the fins and the launch lug. Smooth out the glue and remove excess by sliding your finger along the glue. Lay the rocket in a horizontal position while the glue dries.

� 14. Optional Step: If using a screw-on retainer (NOT INCLUDED), apply CyA adhesive (super glue) to the end of the motor tube, then slide on the externally threaded portion of the retainer. Allow the glue time to dry. The cap can be screwed on later when the rocket motor is installed.

3.5"88.9mm

0.25"6.35mm

7"

0.5"12.7mm

Fin

Sheet B - P/N 31043

� 15. Thread the yellow shock cord up through the rocket body so the end sticks out the top, then tie the free end of the cord to the loop on the base of the shoulder of the nose cone. Put a little wood glue on the knot to make it permanent.

� 16. Cut out the parachute from the plastic sheet using a scissors or hobby knife.

� 17. Place one reinforcement ring on each of the cor-ners of the plastic parachute canopy. Take a sharp pencil or knife and poke a hole through the plastic in the center of each ring.

� 18. Find the white cotton shroud line and cut the string into four equal lengths as shown. Tie the shroud lines through the ring holes as shown. Put a little bit of glue on the knots to secure them in place. Allow the glue to dry.

� 19. Holding the parachute at the center of its top, pull the lines together to even up the ends. Thread the four looped lines through the plastic loop at the base of the nose cone. Take the top of the parachute and pull it through all four string loops at the same time and then pull to tighten the knot. This securely attach-es the parachute to the rocket.

� 20. When all the glue has completely dried, you can paint your completed Zephyr Jr. rocket.

� 21. Allow the paint to harden at least a day before applying the vinyl decals. We recommend removing each one from the paper backing and then dipping them in soapy water to lubricate them so they will slide around and can be repositioned easily. Keep them wet by occasionally dripping some soapy water on the model if they start to grab the rocket too quick-ly. When the decal is in the right location, press down firmly, and squeegee out any water underneath. When the decal dries, it will be permanently fixed. The soapy water will not affect the adhesion of the glue on the back of the vinyl decal.

� Congratulations! Your Zephyr Jr. rocket is now complete!

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Step 18

Step 19

Step 20

Step 17

Step 15

Figure 1 Shroud line

Adhesive circle

a division of APOGEE ROCKETS

1130 Elkton Drive, Suite A

Colorado Springs, CO 80907 USA

www.ApogeeRockets.com

CAREFULLY CUT OUT ALONG DASHED LINE

CAREFULLY CUT OUT ALONG DASHED LINE

STEP 2Press the circle firmly and attach second end to the

circle next to it on the same side of the parachute

(see Figure 2).

STEP 1Carefully cut out parachute canopy along dashed lines.Take parachute

shroud line and cut into 3 equal lengths. Placing the end of each shroud

line over a circle at the parachute corners, secure line with adhesive

circle as shown in Figure 1.

Figure 2

STEP 3Holding the parachute canopy

by the center of its top, pull the

lines together and try to even up

the ends.

STEP 4Pass the parachute lines through the nose cone eye screw. Pass the canopy

completely through the loop ends of the parachute. Pull the lines tightly against

the eye screw and fix the knot in place with a drop of glue.

nose cone eye screw

Step 16

H O2

Step 21

Display Stand AssemblyDisplay Stand Assembly � Remove the display stand pieces from the laser-cut

sheet. Discard the larger disk, as it will not be used on this stand. Assemble the three leg pieces together. The tabs all have to engage in the slots at the same time. The smaller disk is inserted on the bottom cen-tral part of the stand as shown. You may have to flip the disk over if it doesn’t go on easily. Run a thin bead of glue along all the joints between the pieces. When the glue is dry, the stand can be painted and a rocket can be placed on it.

To launch your rocket you will need the following: ● A model rocket launch pad a ¼-inch (6mm) launch rod

and 12v launch controller ● Rocket Recovery Wadding ● Several recommended 24mm Rocket Engines for the

Zephyr Jr. are listed in the motor chart.* *Go to our website for a broader motor selection for this

kit at https://www.apogeerockets.com/Model-Rocket-Kits/Skill-Level-3-Model-Rocket-Kits/Zephyr-Jr#motors

� A. Fold the parachute as shown.

� B. Crumple and insert 5 or 6 sheets of recovery wad-ding into the tube with a long dowel. Slide the folded parachute into the tube behind the recovery wadding. Then slide the nose cone into the main body tube.

� C. When you are ready to launch your rocket, slide the rocket motor into the engine mount tube and wrap tape around the thrust ring and motor tube to hold the motor securely in place (or screw on the retainer cap if using that). The thrust ring on the back of the motors will butt up against the tube, preventing it from sliding too far in.

� D. If you’re using Estes engines that don’t have a thrust ring on the rear, you can make one from mask-ing tape. Wrap 5 layers of tape over the nozzle-end of the rocket motor. It needs to be only over the bottom ¼-inch (6mm). Using a hobby knife, trim off any tape that sticks over the edge of the motor. Note: This thrust ring is plenty strong, and you don’t need to fear that it will allow the motor to move on you during launch. Once the thrust ring is created, install the motor as shown.

� E. Insert and secure the engine igniters as directed on the package the engines came with.

� At this point, the assembly of the rocket is complete and ready for flight. Continue to follow the countdown and launch procedures.

Step B

Step C

Step D

Step E

Step A

Rocket PreflightRocket Preflight

Launch Supplies NeededLaunch Supplies Needed

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*Zephyr Jr. Suggested Motor Chart*Zephyr Jr. Suggested Motor ChartManufac-turer(s)

EngineLoaded Motor Type Est. Altitude

Ft mEstes D12-3 Single Use 203 61.87Estes E12-3 Single Use 459 139.90Quest E26W-4 Single Use 554 168.86

Cesaroni E22SS-5 Reloadable 720 219.46AeroTech E20W-4 Single Use 1054.87 321.52

0.25"6mm

Countdown and Launch ProcedureCountdown and Launch Procedure

Misfire ProcedureMisfire Procedure

� The Zephyr Jr flies off of a ¼” launch rod. Fly your rocket on a large field that is far from any power lines, trees, or low flying aircraft. The larger the field, the greater your chances of recovering your rocket. The launch area around the pad must be free of dry weeds and brown grass. Launch only during calm weather with very little or no wind and good visibility.

� 10. Remove the safety key from the launch controller.

� 9. Slide the rail buttons over the launch rail to place the rocket on the pad. The rocket should slide freely along the launch rod.

� 8. Attach the micro-clips to the igniter bundles. The clips must not touch each other or the metal blast deflector.

� 7. Stand back from your rocket as far as the launch wire allows (at least 40 feet for E motors and larger).

� 6. Insert the safety key to arm the launch system. The light (or buzzer) on the controller should come on.

� Give a loud countdown! 5… 4… 3… 2… 1… LAUNCH!

� Push and hold the button until the engine ignites. Then remove the safety key and place the safety cap on the launch rod.

Occasionally the igniter will burn, but the motor will fail to ignite. If this happens, the cause is that the pyrogen on the igniter was not in contact with the engine's propellant. When an ignition failure occurs, remove the safety key from the launch controller and wait 60 seconds before approaching the rocket. Remove the old igniter from the engine and install a new one. Make sure that the igniter is inserted fully into the engine and touches the propellant. Secure the igniter as directed on the engine package and repeat the countdown and launch procedure. Always follow the NAR* Model Rocket Safety Code when launching model rockets.

*National Association of Rocketry **Kevlar® is a brand name of E.I. DuPont for their selection of aramid fibers. Only DuPont makes Kevlar®.

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Go online and order at www.ApogeeRockets.com or call us and order at 719-535-9335. We’re available M-F: 9:00am-5:00pm MST

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