Below is the construction of a 1.4g (Consumer) single tube firework. The same
type of firework that you can purchase for the 4th of July and New Years. Tubes
like this can also be placed on boards and fused together to make racks for your
finalé.
The photo below shows the tube, cap (round paper disk), plastic base, label, and
the fused firework shell itself. The firework shell can be a shell that will
produce any effect that you want, from a Salute to a Peony. The shells shown
below are a fused, but not filled with stars, #100 canister shell, a complete 2 1/8"
plastic Chrysanthemums ball shell, and on the far right a #5 canister shell
fused and ready to have the lift charge attached. Notice that the
center shell is complete with an attached lift cup with a lift charge and a delay fuse. The delay
of the fuse will be 3 to 6 seconds. The shell
is of no real different construction than that of a professional, drop in the
mortar type of shell, except it is without quickmatch and it is smaller for
legal consumer use. (The construction of these small aerial firework shells is,
or will be soon, located in another section of our website. We will show you how
theses simple shells and mines are made.)

This is how we build these tube items here. The process
starts by cutting or drilling a hole in the paper tube for the fuse to pass
through from the shell. The hole should be at the same size as the fuse used for
the shell.
PHOTO drilling/cutting hole in tube
The fuse for the firework shell is inserted, from the inside, through the hole
in the paper tube. Obviously, the lift charge for the shell goes down toward
where the plastic base will be fitted to the tube. Be careful with the fuse, if
it is "kinked" or seriously bent it may cause the fuse to fail at that point and
the shell will not ignite.
NOTE: If you are making a rack of numerous tubes you would need to make
two holes in the paper tube with a fuse leading out from the lift charge and
into the next tube and shell. The lift charge will start the other fuse and set
off the next tube timed by how long a fuse you have used and how fast the fuse
burns. In this case one continuous fuse will lead to all of the shells, and
slits are made in the tube instead of a hole for the fuse. We have not made any
racks in a while so no photos to show you, but I bet that you can understand the idea.
PHOTO fuse inserted in hole in tube w/ shell in the tube
A few dabs of hot glue are placed inside the groove where the tube will be
placed and also where the shells attached lift charge will sit. The tube and shell are then
quickly installed while the glue is hot. Both the tube, lift charge and shell will then be
held to the base for a more secure hold for handling and shipping.
White glue will work, but takes longer to set up hard, and it will not stick
properly to the plastic when using plastic bases, as we are here.
PHOTO -- PHOTO hot glue on base -- tube and shell glued on the base
The paper cap (disk) is inserted into the top of the tube. It should be glued with
white glue, but it is not necessary as the cap should be tight fitting. A dowel rod
or pipe is used to seat the cap firmly and squarely on top of the shell to hold
it in place, and to keep debris out of the operational parts of the firework.
PHOTO --- PHOTO inserting paper disk cap and pushing in with a large dowel rod
The label is glued in place on the tube. Sometimes we will place an extra dab of
hot melt glue on the outside around the fuse and base for a more secure hold.
Also, we usually will take a small dab of pyrogen (A mixture of Black Powder and
Nitrocellulose.) and put it on the end of the fuse for two reasons. One, it
seals the fuse from spilling powder, and two, it makes the fuse a lot easier to
ignite for the customer. A piece
of tape is then placed on the fuse to mark the fuse location, also known as a fuse
protector. With this fuse protector no powder, from even the fuse, is exposed on the firework
for safety in shipping, handling, and storage.
PHOTO completed firework showing a white/silver OPI fuse protector over an OPI black label