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National Association of Rocketry Dallas Area Rocket Society
3M sanding sponge

Sand the fillets using a 3M Contour Surface Sanding Sponge, Medium 918NA. These are terrific for sanding you rockets. They conform nicely and last a long time. When they get clogged, you can slap them against the pavement a couple of times to clear them up. If needed, you can rinse them out like a sponge (although rinsing them seems to weaken them). I have the finer grain sponges too, but mostly use them for paint.

 
Sanding sponges are also available as sanding blocks which are better for sanding and keeping flat surfaces flat.
 
Recently, 3M has released a similar product called Sand Blaster, that seems to be more "designer" oriented. They are color coded in mauve, mustard and hunter green. I'll use them, but I don't like them as much. It may be my imagination, but the surface seems have soft plastic coat and doesn't "breath" as well. On the positive side, they probably last longer.
Elmers fill n finish and wood filler

Now comes the easy part. Completely cover that fine sanding job with the very mysterious Elmer's Fill 'N Finish. It's tempting to try to apply it straight out of the container, but it helps to water it down a bit. No need to be neat about it. Think of it as a thick primer, 95% of it is going to be sanded off.


 
fillets with fill n finish applied

Fill 'N Finish is a filler and it will happily gum up a perfectly good sanding sponge, so let it dry over night.

Fill 'N Finish sands easily. Sand lightly and gently with the goal being to leave the Fill 'N Finish only in the minor imperfections in the epoxy.

 
fillets with fil n finish applied

Having the dark colored epoxy makes it a lot easier to distinguish between Fill 'N Finish and epoxy.

 
 
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