Parts List:
2 inch PVC:
8 X 45 degree elbow
1 X 90 degree elbow
2 X Tee
2 X end caps
2 X 1 inch inside diameter threaded bushing
1 X 3/4 inch inside diameter threaded bushing
1 X 1/2 inch inside diameter threaded bushing
1 X 10 foot pipe
Other Parts:
1 X 1 inch inlet and outlet valve
2 X 1 inch transition coupler
1 X 5 foot 1/2 inch PVC pipe
1 X 1/2 inch threaded pvc adapter
1 X 1/4 inch inside, 3/4 outside diameter iron bushing
1 X 1/4 inch brass coupler
1 X 1/4 inch quick connect brass air fitting
1 X small momentary switch
1 X 9-volt battery
1 X 9-volt battery holder
pvc primer and cement
teflon tape
So I decided to go with the octagon shape for the base. I thought it would be kinda cool looking. It would actually be a little easier to build the base in sort of a W shape (that way you’d get rid of the 45 degree elbows and use two 90’s in their place. You’d also need a coupler in place of one of the tees for the air inlet.) with the valve in the middle and the inlet in one of the outside “legs” but far be it from me to choose the easy road! I actually only used about 4 feet of the 2 inch PVC pipe, but the store only had it in 10 foot lengths so I’ve got six feet to build another one of these launchers or some other project down the road.
Prep:
First, I made sure my various threaded fittings would go together the way I wanted them to. Then once the valve and inlet assemblies were put together:


I laid out all the parts on the floor to get sort of a sanity check of my design before cutting or gluing anything. It looked pretty good. I glued the bushings into the tees and the 90 degree elbow which would go at the outlet of the valve at this point.
After laying all the parts out in the approximate locations where they would end up I did a little measuring. There was about 1 3/8 inches of space for the pipe to slide in before it hit the stop inside the fittings so I decided I would cut 3 inch sections for most of the way around the octagon. I would need two sections longer than that to accomodate the length of the valve assembly. 8 inch sections would do for that. I could actually have probably gone with 2.75 inch sections instead of the 3s and 7 inchers instead of the 8s but I wanted a little room to fiddle.
I own a 10 inch power miter saw so cutting the 3 and 8 inch sections of pipe and keeping the ends square was pretty easy. With a little care it shouldn’t be hard to do it by hand, either. With all the sections cut I dry fitted the whole thing together once to make sure it would work out the way I wanted it to.
Final Assembly:
Glueing up the joints is easy but takes some time. It should have taken even longer than it did, but I ignored the instructions on the glue to wait 30 minutes before handling. I gave most of the parts about five minutes cure time before moving on to the next joint. Having already glued the bushing into the tees and the 90 degree elbow, I decided to start building the octagon from the tees outwards. There were two tricks to the process, the first being to keep everything lined up so that the octagon would sit level once it was all glued together, and the second to make sure that the last two things glued were the ends of the 8 inch sections that would tie the whole thing together. Glueing the 8 inch sections was a bit tricky because the pvc cement hardens fairly quickly and I had to do two joints at once right at the end. In the end one of the 8 inch sections didn’t go all the way into the elbow so my octagon is slightly skewed, but I think it sealed all right:

I’ll know for sure when I get it up to launch pressure of between 90 and 110psi. The last step was to glue the section of 1/2 inch pipe into the fitting with a threaded end and screw it into the bushing at the end of the 90 degree elbow.
I waited two hours for the joints to cure, then pressurized the assembly. I built it up to about 60 pounds then tried the valve. It seemed to work pretty well. That was the end of the first build day. I haven’t got a switch for the valve yet so I’ll update this post once I’ve done that.
Here is the finished product sans paint and the switch:

I ordered a fun switch from thinkgeek and I think I’ll use it as an “arming” switch wired in series with a momentary pushbutton for the launch switch. I’ll mount them in some sort of case from Radio Shack or maybe build my own.