I originally set out to build a replacement for my wrecked clone of an Estes Black Brant III.  But along the way decided it would be better if it was larger.  So I developed a true-to-scale model of the Black Brant III using BT-60 tubing and make use of the 3D printed fin can sold on Shapeways.  The 3D printed part was kind of pricey, but I considered it an experiment to study to viability of 3D printed parts in rocketry.

That actually made the construction pretty simple - build a motor mount, glue it into a tube and the tube onto the fin can.  One of the three 3D printed fins was a bit uneven, as though the print resolution suffered in that area.  It needed a bit of sanding and filling to even out.  The nose cone is balsa, from Semroc.  Also, the body tube is two pieces, joined by a baffle.  The real BBIII appears to have a mid-body joint seam, so I intend to leave the joint between the two segments unfilled.