Okay here goes....The following descriptions and images below are presented for informational purposes
only! Rocketry is an inherently dangerous hobby. Use common sense and safety equipment and safe practices
when engaging in rocketry or rocketry related activities. Most of all follow the local, state and Federal laws
governing rocketry activities.  

You start off with 2024 T3 1" O.D. .083 wall aerospace grade tubing cut to a length 7.5"






Using a boring bar fitted with a 90deg grooving bit cut an inside snap ring groove .040 deep .250" from
each end.

Mic the snap ring you plan to use (e.g. McMaster-Carr ) to determine the width of your snap ring groove.

Be sure to have inner most point of the groove arrive at .250 from the front of the case.

This is most easily done by scribing at that point in the tubing and cut from that scribed point toward the
front of the tube to create the grooves width. This will help to keep your interior dimensions in whole
numbered measurements.

You will cut your exterior thrust ring groove .040 deep .125 from the front end of the case tube and mic
your lap-ring to determine your groove width. When making each of these grooves work slowly.

Once you have completed all of the grooves, test fit your snap rings.

Next you'll need dense graphite block at least 1" thick to cut a nozzle slug. You also need a 1" hole saw.






You'll want to remove the drill from the chuck of the hole saw before you cut out a slug of graphite.






Cutting graphite slugs is easiest done with a drill press, although a hand drill could be used.  You will need
to have a vacuum running to remove graphite dust as you cut slugs from the graphite slab and wear a dust
mask and clothes you don't care much about. Keep in mind that graphite dust can easily short out electronics
and electric motors that run equipment.

Here is a cut slug:




Mic the I.D. of your case tubing (should be 0.834") and turn your slug down to 0.830" and face the slug to
a final length 1.500". At the middle of the slug (0.75") you will want to cut a groove to accept
BUNA-N O-ring (McMaster-Carr) the size I use is Inside Diameter .706" Outside Diameter .900" 3/32 width.

Carefully cut the groove and trial fit the o-ring on the nozzle periodically, until you can slip the slug
with the fitted o-ring into the lightly greased case tube without cutting the o-ring.

However, it should take some effort to install the nozzle. Remove the nozzle using a hardwood dowel.
For the fore closure cut a 1.500" (or slightly longer for facing) piece of 2024 T353 aluminum rod stock.

Cut the same o-ring groove at 0.75" for the same size o-ring used for the nozzle. Use the same trial fitting
until you get a snug fit. Now at this point you can drill and tap the closure for an eye-bolt for using in
electronic recovery. Or using your lathe and a 5/8 drill bit you can cut a delay grain well to the same depth
as the length of a Aerotech delay grain.






On the opposite side of the closure drill a 3/8" well for the ejection charge being careful not to drill
through to the delay well. Use a 1/16" drill to make the flash hole between the delay well and the ejection
well.






You now have a motor well suited for "F" to "G" experimental loads. The grain length for this case is
4.000". For a starting point I use a single cast grain with .250 core and a drilled nozzle throat of 0.125".
This is well suited for KN/SO propellant. The motor in the video below used RNX 71V propellant, single
grain with a .250 core and a nozzle drilled with a wire gauge bit sized 0.116".
Building the Compliance "F" Impulse Motor