While I'm happy with a the performance of my 1" diameter motors, I caught the bug that bigger is better. To keep going along with that idea I've progressed to using 1-1/4" PVC. This doesn't seem like a big difference but just look:

I do feel that this motor might be a bit excessive, but bigger is better right? It maxed out the motor tube of the rocket and should really let her scream.

This new motor design also requires a new boring tool width of 5/8". The local stores only held this stock in hardened steel, so the angle grinder was used to give the rod the necessary piercing tip that is necessary for boring through hot sugar efficiently. I then sanded the rod down to 1000 grit sandpaper for ease of removal after casting.

Also, when working with motors of this size things need to be precise. 1/2" machine washers are not 1/2" they are meant for 1/2" hardware. I obtained washers very close and then drilled them out with my drill press to the proper size.

For sealing the nozzle and cap I'm also using ultra high temperature gasket RTV sealant. Can't be stingy either. There's a serious amount of power in these things. The nozzle is still created with anchoring cement with a steel washer for the choke, and the cap has a layer of cement also before being coated with the RTV sealant.

Video of the full size test will come when I find a proper test range for this monster of a motor. Safety is a huge concern.