What follows are a series of images showing the assembly of a 38mm I140 motor.

Here is a view of the all the parts of the 38mm motor system.

The following tools will be required for assembly

Start by cutting a length of nylon fill tube, and selecting the appropriate motor tube and injector. Place a DASH#213 'O' on the combustion chamber side of the nozzle and injector.

Next, place an ignitor grain, complete with ignitor over the fill tube.

Following this, place the ignitor assembly into the injector, threading the fill tube up through the injector from the combustion chamber side.

Place a compression sleeve over the exposed nylon fill hose.

Place a compression nut over the sleeve and hose, and tighten with either a 3/8" (1/8" fill tube) or 7/16" (3/16" fill tube) wrench.

Trim off the excess fill tube

Place the injector and ignitor grain assembly into a fresh fuel grain, and thread the nozzle over the free end of the nylon fill hose and ignitor wire. If necessary, use masking tape to ensure that the ignitor grain is a very snug fit into the fuel grain.

Grease the injector 'O' ring with suitable PTFE grease

Slide the nozzle, fuel and injector assembly into the nozzle end of the motor tube

Screw on the nozzle end closure

Screw on the tank end closure