I started by glassing the body tubes. I'm trying the tube sock system to glass the tubes. Giant leap sells this product for way too much. All it is drainage tube sock that sells for $20.00 at Home Depot for a 4 inch x 100 foot roll. It can stretch to about 8-9 inches in diameter. For bigger rockets, they make an 8 inch that can stretch up to 24 inch for your really big projects. One thing about the tube sock is does soak up a lot of epoxy because it is a knit versus a weave like fiberglass. But it works well and it easy to work with once it's stretched onto the tube. I tried to glass three layers at one time and it came out ok. I recommend doing one layer at a time.
With the tubes being four feet long, I found this to be an easier way of glassing the tubes. It does however take more time because to lay it up. You must let the first sock setup with the epoxy for about 1 hour before the next sock can go on. Since I was using an epoxy with a two hour working time, it took a few hours for each layer. I let the epoxy setup for 24 hours to dry completely and it also allowed the epoxy to soak into the body tube real good.
I found through trial and error that the easiest way to use the easy sock is to first cut the length about 8 inches longer than the body tube with out stretching it. I used some wire to tie tight around the ends to keep it from moving. Once it’s tight at one end, I pulled the other end over the tube. Then using one hand to hold the end around my poll as it was being stretched while I used my other hand to pull it tighter. Once it was stretched tight, I used my free hand to tie another wire around the cloth and poll with another wire. I then twisted the wire tight so the wires and sock would not move.
Now the tubes was ready for the epoxy. With all the supplies waiting, I mixed up about 8 oz. of epoxy. I start by using a popsicle stick by applying epoxy at both ends first to make sure they get coated well. I also made sure it soaked all the way to the cardboard. Again after trial and error I found that turning on my rotisserie motor and letting the body tube turn slowly and using a Bondo rubber applicator, I slowly poured out the epoxy directly onto he body tube and used the applicator to guide the epoxy over the body tube. That way it took only about 5 minutes to apply epoxy over the entire body with real good coverage. Then using the popsicle stick and the left over epoxy, I applied epoxy in the small areas that needed a little more epoxy or where dry spot showed up. As the tube turned I also used the Bondo applicator to pick up excess epoxy and put in the places that need it.
Once the epoxy has set a bit, I put the next sock on. You want the epoxy to be just a bit tacky but not too much otherwise it will be too hard to get the new sock over the one currently drying. I found that if you roll it up, it makes it much easier to unroll right down the tube. You still have to pull it tight as you unroll the sock. Start by wrapping another wire around the end of the new sock just where you wire wrapped the first sock. Don't undo the first sock wire unless the first sock is completely dry (24 hours more or less depend on the epoxy you use). Once you have the wire tight you start by pulling the new sock tight over the end. Make sure you have no folds or high spots at the very end. If you do, just pull the sock tight until they are gone. Don't pull too tight or you will tear the sock. It will stretch quite a bit before it tears so you should be ok. Just be careful and just work with the sock. Once you have the sock ready with no folds etc, just start to unroll the sock and pull it tight as you go. Continue to unroll and tighten till you get to the other end and pull the ends tight. Hold the end of the sock with one hand and use your free hand or a partner to wrap a wire around the other end. Before you tighten the wire tight and can pull the fabric tighter while holding the wire then tighten it.
Ok, you are ready to apply the epoxy to the second sock. Again about 6 to 7 oz. of epoxy needs to be mixed up for this layer. Again start at the end first making sure they are soaked and coated at least one inch from the end of the tube in on both sides first. Then pour out your epoxy onto you body tubes and work in your epoxy into the sock and touching up dry spots with a popsicle stick. I usually let the motor run for about an hour or two to make sure you have no high spots or pooling of excess epoxy on your body tube. I have found that the constant turning of the rotisserie motor works great for making smooth epoxy surfaces if you just let it run. No drops, no pooling or high spots when doing your final coat of finish epoxy. You get a smooth glassy finish epoxy shine every time.
