P/N 10569

Skill Level 4 - Moderately Challenging

This 98mm Dual-Deployment Conversion Kit allows you to modify a 4-inch diameter rocket to use for dual deployment. It is great for kits like the Apogee Zephyr rocket. By doing this, you can take a rocket you’re familiar with and add the ability to acheive recovery by dual deployment. The whole purpose of dual-deployment is to try to get the rocket to land closer to the launch pad so you don’t have to walk as far to retrieve it.

Dual Deployment Conversion Kit

Item Item Name Qty

10215 AT-98/1” Switch Band Ring 1

10218 AT-98/18” (4” Thick Wall Tube) 1

13075 Removable Plastic Rivet 3

13086 ¼-20X9: Full Thread Rod 1

13093 ¼-20 Wing Nut 1

13119 Coupler Bulkhead Stop Ring 2

13125 AC-98 2

15420 Ebay Sled plate ¼” Plywood 1

15421 Ebay Bulkhead-A ¼” Plywood 1

15422 Ebay Bulkhead-B ¼” Plywood 1

15423 Ebay Threaded Rod Support Piece ¼” Plywood 2

29092 18” Nylon Parachute 1

29364 12”X12” Parachute Protector 1

29627 ¼-20 Eye Bolt 2

29627 ¼-20 Nut 6

29628 ¼-20 Flat Washer 6

29560 1/2” Tubular Nylon Webbing X 15 feet 1

31232 Instruction Sheet A 1

31233 Instruction Sheet B 1

41039 Dual-Deployment Conversion Kit Decal 1

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Other Tools and Materials Needed

• Hobby Knife • Ruler • Super Glue • Epoxy • Sandpaper 200 grit • Masking Tape • Pencil • Paper Towels • Liquid dish washing soap and a bowl of water • 5/32” drill bit and portable electric hand drill • Adjustable wrench • Spray paint: Per your color choice

Optional Tools / Finishing Supplies

• Plastic Sheet (to cover the work surface) • Safety Glasses (for general protection while building and painting)

P/N 31232

Ebay Assembly

� 1. Sand the outer edges of the two end disks smooth so that they are easy to install/remove from the remaining coupler tube. Also, round over the edge (opposite the Apogee logo), to help aid in the installation of the disks into the tube.

� 2. Using wood glue, attach the two threaded rod support pieces into the middle slots on the ends of the plywood sled plate (on the side without the Apogee logo). Allow the glue time to dry.

� 3. Using wood glue, attach the bulkhead with the single slot to the plywood sled as shown. Add a glue fillet to strengthen the joint, and allow the glue time to dry.

� 4. Glue the two “stop rings” into the ends of the long coupler tube.They are recessed ¼ inch (6.4mm) from each end. Wipe off any excess glue so that you can insert the two bulkheads into the tube later.

� 5. Attach the eyebolt to the remaining bulkhead has shown. The “eyelet” is inserted from the side of the disk with the Apogee logo on it. You will also need two washers (one on each side of the bulk-head), and two nuts. Tighten the nuts so the eye-bolt doesn’t rotate.

� 6. Attach the remaining eyebolt to the bulkhead/sled has shown. As before, the “eyelet” is inserted from the side of the disk with the Apogee logo on it. You will also need two washers (one on each side of the bulkhead), and two nuts. Tighten the nuts so the eyebolt doesn’t rotate.

1/4”

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� 7. Put a washer and nut onto one end of the long threaded rod. Insert the rod through the bulkhead and the support pieces below the sled.

� 8. Mark the coupler 3-½ inches (8.9 cm) from one end. Slide the switch band over the coupler and glue it into place along the line you just made. This should center the band in the middle of the cou-pler.

� 9. After you mount your electronics on the plywood sled, you can slide the sled into the coupler tube. For tips on installing your electronics, see our videos at: https://www.apogeerockets.com/Advanced_Construction_videos/Rocketry_Video_111

� 10. Install the last bulkhead onto the sled by inserting the two tabs into the slots and the threaded rod through the middle hole. Screw the last washer and the wing nut onto the threaded rod to secure the bulkhead into the ebay.

� 11. Tie the free end of the nylon shock cord to the eyebolt on the base of the ebay. The bottom will be the side with the long slot and the regular nut. (NOTE: You can wait and then perform this step after the rest of the assembly has been completed, as you will need to drill holes into the ebay to vent your electronics and for the removable rivets that that hold the parts together for launch.)

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P/N 31233

� 12. Cut out the marking guide from from the tem-plate sheet, and wrap it around one end of the long 4-inch diameter tube. Align the edge flush with the end of the tube, and tape it in place. Using a sharp pencil, poke a hole through the paper at each of the three cross-hairs to mark the location for drilling holes. You can then remove the marking guide.

� 13. Using a 5/32 bit, drill three holes into the tube at the marked location. Clean up the edges of the holes with sandpaper as necessary.

� 14.Temporarily remove the sled from the ebay and set it aside. Insert the ebay tube into the long tube on the end with the holes. Put a piece of mask-ing tape over the joint so the pieces can’t rotate. Make a pencil line across the joint between the two tubes. This is called a “witness mark.” The purpose is to line up the tubes later to make assembly easier. You may want to make it permanent after you paint the rocket.

� 15. Using the holes in the long tube as a guide, drill through the three holes into the ebay tube cou-pler. Separate the tubes by removing the masking tape, and clean up the edges of the holes with sand-paper as necessary.

� 16. Reinstall the sled and the bulkheads into the ebay. Tie the shorter shock cord strap onto the eye-bolt on the forward bulkhead of the ebay. Then pass the shock cord through the tube with the holes; the holes oriented toward the ebay assembly.

� 17. Line up the holes in the tube with the holes in the ebay. Insert the three reusable plastic rivets into the holes. The base gets inserted first, and then the plunger part next. The plunger separates the fingers at the base of the base section, which holds the rivet in the hole and keeps the two parts together. If you need to remove the rivet, insert the edge of a knife under the plunger section and gently pry it up. Then repeat the process with the knife edge to pry the base out of the tube. The rivet is reusable and can be reinserted back into the hole when you’re ready to fly your rocket.

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6”

Large Parachute

� 18. Install the included parachute protector into the parachute tube by tying it on the shock cord. Try to get it close to the end of the tube.

� 19. Tie the free end of the shock cord to the loop on the base of the nose cone.

� 20. Remove your large parachute from your rocket and re-attached it to the base of your rock-et’s nose cone. Attach the smaller parachute from this conversion kit to the eyebolt at the base of the ebay. Holding the parachute at the center of its top, pull the lines together to even up the ends. Thread the looped lines through the loop at the base of the nose cone. Take the top of the parachute and pull it through all string loops at the same time and then pull to tighten the knot. This securely attaches the parachute to the rocket.

� 21. Paint your new conversion kit as desired. Allow the paint to harden at least two days before applying the vinyl decals. The decals are somewhat stretchy, so be careful applying them. We recom-mend 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 reposi-tioned easily. Keep them wet by occasionally drip-ping some soapy water on them if they start to grab the rocket too quickly. 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.

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SmallParachute

Prepping your rocket for flight

Set up your electronics in the ebay of the kit, along with the ejection charges.

For help in this set-up process, see our tutorial videos on dual-deployment at:

https://www.apogeerockets.com/Advanced_Construction_videos/Rocketry_Video_120

https://www.apogeerockets.com/Advanced_Construction_videos/Rocketry_Video_121

Wrap the parachutes completely in the parachute protectors before inserting them in the rocket.

Page 6www.ApogeeRockets.com

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