And for anyone following this, the reason that Castor's is longer is that I did not drill out the rivets to separate the intermediary piece.
Prior to removing the nosecone I had to remove the 4 tunnels on the nose as well as one on the main body. The tunnels are just that, aluminum fairings that provide protected channels for the electrical, hydraulic and fueling systems. They were designed to protect these systems from the atmosphere but not from manhandling. Here is one that took some abuse and will need to be repaired:
These tunnels are screwed into machined stand-offs which in turn are screwed into the missile body. After working through several dozen using a variety of dis-assembly techniques, the best means of removal turns out to be drilling the hardened screw head out
BTW, I would like to send out a sincere Thanks to Bob Price for a really great tip on how to do this economically:
While making a knife I found a way to drill really hard steel (R60) Tungsten Carbide bits are insanely expensive and the blade had burnt up even cobalt bits. What to do? I had a cheapie masonry bit, I dressed it on a diamond stone to lower the trailing edge of the carbide so it looked like a bit for steel. Damn if it didn't drill right through!
With the screws out, the tunnel comes off and the stand-offs can be removed with a socket and an impact gun (of course I will need to create new ones for assembly).
So at the end of the day I am getting towards the end of dis-assembly. There are two more primary pieces on this missile to remove and then it will be grinding, sandblasting and structural reconstruction for the pair.
So, 'til next time.....