Bar Fly 4-in Dia. High Power Model Rocket

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Change Log:
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12/23/2025 - By request, added a one-piece fincan.  It's big and gnarly, so buckle up!
12/23/2025 - The offset for the threaded parts was a little tight, so I reduced the threaded parts by 0.2mm.  Just the sleds and the tailcone (suffixed with R2).  The nosecone base and fincan were untouched
12/27/2025 - Opened up the throat for the fwd end of the tailcone.  This will make getting a 75mm motor case thrust ring/aft closure into the tailcone.  I also dropped the shelf that the thrust ring rests on, so you can use a motor adaptor back plate.
12/27/2025 - Fixed the AT 75mm motor case; the Aft closure/thrust ring was the incorrect size.
01/02/2026 - Added split fin models - based on printer tolerances, the dowels may not fit.  You will need to print 8 of them.  Try printing 1 and check the tolerance.  If it's too big, scale down by .2 or .3mm in all directions.  
01/04/2026 - Added an AV Sled with vertical openings for securing payloads/avionics.  Bottom holes on vertical will allow for an XT-30 connector
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Meet Bar Fly: a big, unapologetic, 3D‑printed rocket kit for builders who already know which end points up and aren’t afraid of motors that make the LSO mutter into their clipboard. This isn’t a “my first rocket” situation.  This is a seriously cool, badass, ripper of a rocket.  Bar Fly delivers in spades, plus a little chaos for flavor.  It was inspired by Mac Performance's Black Fly.  If you want a professionally built kit, you should go buy one.  They're not very expensive, and it's overflowing with attitude!

You get a full suite of printed parts, hardware mounting points, and flight computer mounting options — all designed to go together cleanly if you treat them with the respect of a seasoned rocketeer and not the enthusiasm of a caffeinated raccoon. Build it right, and Bar Fly will reward you with flights that make people ask, “Wait… that’s 3D printed?”

Parts List (a.k.a. The Stuff You Get to Play With)

• Nosecone + AV Sled Options – Threads together like it means business.

• Mid Section – The classy middle child of the airframe.

• Base Section – Where things get serious and your AV sled rides first class.

• Fincan + Fincan Coupler – The structural backbone preventing your rocket from having an identity crisis.

• Aft Coupler – The emotional support piece keeping the back half from filing for separation.

• Hardware Spots – For all the shiny bits that make you feel like a rocket metalsmith.

• Black AV Sled – A blank canvas for whatever glorious electronics throne you decide to build.

• OpenRocket Simulation File - zipped up for convenience (and Printables compliance)

• Build Guide - The most hand-holding you're gonna get from this project

Oh no!  The Safety po-po are here:

Yes, Bar Fly is fun. Yes, it’s spicy‑motor friendly. But it still obeys the laws of physics, aerodynamics, and the RSO who will absolutely eviscerate you if you show up with questionable decisions. Build smart, print strong, use decent adhesives, and follow your local rocketry safety code like the responsible gremlin you are, or Bar Fly will judge you... Publicly! 

Bar Fly wants to fly — not redecorate the field with your parts.

Bar Fly isn’t here to hold your hand. It’s here to reward good decisions, punish bad adhesives, and look fantastic doing it. Print strong. Build smart. Fly spicy. And when it lands (or doesn’t), you’ll know exactly what you did right… or gloriously wrong.

Now go make something loud. Bar Fly is watching. And judging. Lovingly.

I will have a companion forum thread on The Rocketry Forums for this rocket.  You can watch me, and others build, and enjoy the stink-eye that everyone shoots my way as I make questionable decisions.

If you enjoy this model and kit, I would love for you to post a Make (with pictures and videos) as well as a Like.  I also have a BuyMeACoffee page, and a donation would be appreciated if you can.