Goal of this project, is to create an authentic looking model of this rocket here, the MGR-2 Honest John tactical missile.

Second of my custom rocket construction projects. This is the also the 2nd of my semi-scale rocket builds. The first (DD05 V2) was mostly a simple modification of a single rocket kit. This project is based primarily on parts from an Estes LoadStar rocket kit, with significant modifications.

I decided to start off with the most challenging part of the build. Construction of the warhead section. The orginal real Honst John (MBG-1A and MGR-1B) had a rather unique bulged section to house the warhead. It took a few days of considering several methods of accomplishing this before it was clear that no intermediate tube was even required. Having all the parts I needed already I started the build.

Normally the parts are separated at the waist section in the middle, creating a seperate nose cone and payload adapter section. That middle part was not needed at all, and if used would have created a warhead section that looked very little like the original.  To produce the desired result, the upper and lower sections would be chemically welded together.

Following the fusing of two sections, fine filler was applied to all the joints and mold lines and set aside to harden.

After the filler dried, and finish sanding completed, the assembly has taken on the desired look.  The warhead’s boat tail is shorter on my semi-scale attempt than the real rocket.  This is an important point to consider later in the project.

Checking scale of the nose and body, compared to a good side view of the real deal.   Measuring, the photo was within 80% of the size of the final product.  Considering the boat tail on my warhead section is shorter, I adjusted the body section proportion to give me a good overall length and look.   Yes, this is a semi-scale project using off-the-shelf parts.

To be continued….

Construction History

11-Oct-2009
Began construction of custom warhead section from LoadStar nose and payload adapter.

12-Oct-2009
Finish sanding of the nose section. Checking scale and calculating a reasonable body tube length.