The 2008 Saturn I model is the most complicated project I have ever worked on.  I learned a lot of things in the process that may someday lead to other complicated projects in the future.  Think about the number of different parts and details of Saturn I's that make them complex vehicles to model at any scale--and that's just for a static model that cannot fly.  Add to that the weight and logistical constraints of successfully flying a clustered and staged model.  Add to that the space requirements of radio control gear.  Add to that limited chute space due to RC gear.  Add to that a list of several potential designs for the internal structure--none of which are perfect.  And that's just the design phase.  Add to that the degree of difficulty in construction and the need for precise fit of major surface details on multi-angled airframe surfaces without using any filler for gaps (because the parts are assembled after painting)... you will begin to picture the complexity of this project.

Left:  SA-5 on launch pad prior to launch (photo courtesy George Gassaway)

While the boilerplate used a few standard tubes, the competition model employs custom tubing for all but the internal structures (stuffer tubes and motor mounts).  Each of the eight scale booster tanks is made from spiral-wound gummed paper tape just like in the original boilerplate, but coupled with a small section made of cardstock at the base.  There are four tubes of varying diameter constructed of 1/64" plywood rolled against the grain.  The majority of the nose cone, as well as two other major tapered body sections were also rolled from plywood (I cannot recommend this technique more highly--thanks again to John Pursley and James Duffy for this method.  Click here for James Duffy's description of the method.).

Most model rockets have major components that are glued together.  The 2008 Saturn is assembled such that many of the parts can be adjusted, removed, and/or replaced if necessary (though not all parts), including parts such as individual fins, certain details, and tank tubes.  Several #2-56 screws (some in conjunction with blind "T" nuts) are used to hold the "loose" detail parts onto the subassemblies, or hold multiple subassemblies together.  The benefits of using lightweight screws instead of glue are pretty obvious:

Another unusual feature of the competition model is the extensive use of Monokote Trim film (yeah, the sticky stuff, not the iron-on stuff).  John Pursley used this method on his 1:10 Vanguard and 1:12 Mercury Redstone projects (he also used iron-on Super Monokote, but I have not yet mastered the art of  iron-on coverings).  The finish is durable, consistent, and covers over a multitude of surface imperfections.  It also provides an excellent slick surface for adhering decal material.  The results are well worth the effort to experiment with this stuff. With practice one can apply it dry over some surfaces (I covered my fins this way), or over primed & sanded (smooth!) surfaces with the water w/dish detergent method (my tail section, interstage, and most of my S-IV stage were covered this way).  I was able to cover my black tanks using the dry method, but I had to contend with some bubble formation due to imperfection in the "straightness" of the tubes.  The following is a breakdown as to the use of primer/paint vs. Trim Monokote on the Saturn's parts:

That would be Jess and Kevin.  Jess, along with her unending encouragement, poured rubber molds, made castings, sprayed and sanded primer, made all the parachutes used in the test models and competition model.  She even designed and built the the transport box that we used to carry the model to NARAM-50.   Kevin Johnson encouraged and nagged me until I finished the model.  He helped with the preflight prep at NARAM-50 by charging batteries, packing chutes, etc... and stayed up late with me one night to help me get the CG correct.  Thanks, Kevin!

I currently own the 2nd edition of Tim Van Milligan's Model Rocket Design and Construction which discusses the ins and outs of designing and constructing all sorts of rocket projects, including techniques that many experienced rocketeers may not have thought about.  One thing of particular note is Tim's emphasis on practical lightweight construction techniques.  In my opinion, there is a tendency in the rocketry community to make heavy, "overbuilt" rockets that could be made both sturdy and relatively lightweight if the proper techniques are utilized.  This is something that I have tried to accomplish throughout the Saturn I project using many of the experimental techniques that you see on our site, and so I appreciate it when I see other rocketeers doing the same.

Apogee just recently released the 3rd edition of the book, which promises to be significantly better--and still at a decent price.  It has lots of good practical information that will help you from start to finish with all your rocketry projects--not just scale.  So stop by their site and check it out.