Quick match is a type of fast-burning fuse that can burn anywhere from 100 to 300 feet per second.  It consists of two parts: a cotton string impregnated with black powder (known as "black match"), and a loose-fitting paper tube (known at "pipe"), usually about 1/4" in diameter, that surrounds the black match.

Whereas normally the large amount of hot gases and sparks generated by the black match are given off into the air, the constrictive match pipe causes the gases to shoot down the tube in front of the actual flame front, which in turn ignites the next portion of fuse and generates more gas, and so on.  This results in a very high velocity flame propagation (or, in laymen's terms, "that there fuse don' burn real fast like!")

Using quick match is a great way to light many fireworks at virtually the same instant, such as aerial shells and aerials. When you combine quick match with the use of an electrical firing system, you have the ability to put on a great, professional looking show.

Please be aware that in the United States, quick match is considered a 1.3G item (the same hazard category as display fireworks), meaning that an ATF license is required to purchase and use it.  Because of the unfortunate ambiguity in many fireworks/explosives laws, there is some debate over whether or not the personal manufacture/use of quick match is legal, and whether or not connecting 1.4G consumer fireworks with quick match makes the entire setup a 1.3G device (after all, many 1.4G cakes contain quick match).  If you decide to make and use this type of fuse, do so at your own risk.

PART A: Black Match

GENERAL MATERIALS

- black powder (Goex brand - don't use pyrodex)
- dextrin (see below) 
- cotton string (NON-WAXED - it must turn to ash when burned, not melt)
- latex rubber gloves

The process of making black match is relatively easy, but is also quite messy - when making it, you will want to where clothing and shoes that you don't mind getting stained.  There are two methods for making black match - the traditional way, which uses a simple machine to soak the strings in black powder solution, and a simpler (albeit slightly more messy) method I devised, which involves manually applying the liquid slurry mixture with your hand.

Method 1: Hands

ADDITIONAL MATERIALS

- a plastic container that you can fit your hand into, such as an old Tupperware bowl

Before you start, be sure that there is no rain in the forecast for the next couple of days.  First, you will need to find a suitable preparation area outside, away from dry grass or other flammable materials (in case the match were to accidentally ignite).  The area must have two objects, approximately 15 feet apart, between which you can place several runs of string - i.e. two small trees, fence posts, a swing set, etc.

Determine approximately the number of feet of fuse you wish to make (I usually do about 100), and cut twice that amount from your roll of string.  Make sure this amount is approximately divisible by the distance between your two poles, with a little extra.  Tie the two ends of the string together, then tie one end of the giant loop around one of the poles.  Loop the string around the opposite poles, then bring it back to loop around the first, and so on.  Each piece of fuse will actually consist of two strings ("two ply") that are together covered by black powder. 

For the fuse composition, you'll need dextrin, black powder, and water.  Dextrin is a binding composition used to hold mixtures pyrotechnic mixtures together.  In this case, it’s used to hold the black powder onto the string.  It's crucial that you have enough dextrin in the mixture, or else the black powder will simply flake off the string when it's dry  You can buy big bags of it from pyrotechnic dealers (such as Skylighter or Firefox), or make your own. 

To make dextrin, spread an entire box of corn starch out on a cookie sheet and cook it in the oven at 400° for about 2 hours, stirring it every 20 minutes or so with a spatula to keep it from burning.  When it's done, it will be light yellow/gold in color.

Mix 20 parts (by weight) of black powder and 1 part dextrin in the bowl - please note that these are mass units, not volume. If you don't have access to a scale, you can measure by volume - mix 4 tablespoons of black powder along and 1/4 teaspoon of dextrin in the container. Note: I usually make twice or three times this much. Use a plastic spoon to stir the dry mixture together. When it's completely mixed, slowly begin adding hot (near boiling) water while mixing until the composition has about the same consistency as tomato soup. The water must be hot in order for the power grains to completely dissolve. Do not drink the mixture. 

Put on your rubber gloves, cup your hand like you're taking a small item that somebody is handing you.  Your fingers should be curled inwards slightly, making a small well in your palm.  Dip your hand into the black powder mixture once it's cool enough to touch, allowing the mixture to flow into your hand.  Lift your hand out of the bowl, extend your fingers slightly, then wrap them around the set of two cotton strings in such a manner that the strings come into contact with the liquid.  Your hand should look as if you're holding onto a half-inch diameter rod - that is, they should not be clamped tightly around the strings.  Slowly begin moving your back and forth along the strings, making sure that they get covered (and stick together), and work you way down.  It will take a bit of practice to get a feel for this (during which a lot of the mixture may drip out of your hand), but eventually you'll be able go quite fast.  I find that I often have to curl up my pinkie finger a little more than the others to prevent the liquid from continuously running out.  Once you begin to see bare spots on the string (or you can feel that there's nothing left in your hand), dip it into the bowl and get some more of the mixture.  I have noticed that the black powder can absorb quite a bit of water while in the bowl, so you may have to add more water every so often.

After you have all the strings coated, let it dry for several hours.  Obviously, in warmer climates, this may not take very long.  After this, repeat the above procedure to add a second coat.  The leftover black powder mixture will be cold and probably much more viscous, so just add more hot water until it thins out.

Method 2: Black Match Machine

ADDITIONAL MATERIALS

- a small plastic tupperware containers (see images below)
- wood scraps (2x2s work well)
- 1/4" wooden dowel chunk

Building the Machine

This method of manufacturing black match employs the use of a "machine" which draws string through a liquid solution of black powder.  It's easy, efficient, and keeps your hands fairly clean of messy black goop.  

First, obtain a small, plastic container used for storing food.  You can get them at Wal-Mart or Rite Aid for relatively cheap.  Drill a couple holes on opposite sides, near the bottom, just big enough for your dowel to pass through and be about a half-inch from the bottom of the container.  See the picture on the right for reference.

Now you need to make holes for the string to pass through.  Using a drill bit that's the same diameter as the cotton string, drill two holes about 1 inch apart right under the lip of the container.  On the opposite side, drill another hole that's slightly larger (big enough for two strings to comfortably pass through).  All of these holes should be oriented 90° off from where the dowel passes through - that is, two separate strings should be able to enter the two holes, go down and under the dowel, and come up and back out one hole.

The last step in making the machine is to create a frame for the string/container assembly.  I used a 1 foot length of 2x2, and drilled two holes about 4" apart.  I glued two scrap pieces of dowel into these holes (each about 5" long) to serve as posts to hold the rolls of string.

On another 1 foot length of 2x2, use epoxy or some other high-strength glue to attach the plastic container to one end.  Attach the string-holding piece of wood to the opposite end using "Liquid Nails" or wood glue, so you end up with the thing pictured on the left.  Be sure that the side of the container with two holes is facing the dowels.

This completes the construction of the "machine", and now you're ready to begin making black match.  As with the first method, you need a place to wrap the wet match strings around so they can dry.

Using the Machine

Prepare a liquid black powder slurry just as you did in the first method, and make sure you have two objects to wrap the finished fuse around.  Put the two spools of string on the dowels, and run both strings into their separate holes, under the dowel in the container, and back out through the single hole.  Tie them together with a big knot so they can't slip back out.  

Take the hot black power mixture and the machine over to the drying area.  Attach the outcoming strings (the ones you tied in a knot) to the first tree/post, and carefully pour the black powder mixture into the container on the machine.  It should completely cover up the dowel that the strings go under.   Now slowly begin walking backwards towards the other drying post.  As you do this, the strings will come off of their rolls, enter the container, go under the dowel and become coated with the mixture, and emerge as one fuse. (see diagram, right)  Yes, that's right, ONE fuse.  Don't separate the strings.  Two strings coated in black powder are much more reliable than one - notice in the picture to the left  that the powder completely fills in the gaps between the two strings.  Because of this, there's a lot less of a chance that the fuse will burn out when lit.

Keep walking at such a rate that the strings moves through the mixture at about 2 inches per second. When you get to the second post, just wrap the string around it and head back towards the first one. Occasionally you may have to add more water to keep the black powder solution from thickening up too much and not adhering to the string. When the level of solution drops to where the dowel or the fuse start coming out with bare patches, it's time to add more solution or stop making fuse. If you want to stop, just continue walking to whichever of the two posts you're closest to, tie it off, and cut the string. Take the string rolls completely out of the machine and wash it out well with water. 

PART B: Quick Match

MATERIALS

- black match fuse
- roll of low-weight (~30 lb) Kraft paper
- low temp glue gun and glue sticks
- scissors or sharp knife
- 5/16 inch dowel rod, 20-24 inches long

Procedure

Low temperature glue guns can be bought at any craft store for just a couple dollars.  The reason to use low temp is because it won't hurt your fingers when you touch it.

Begin by making the paper tubing the match will go in.  Cut off 2-3 foot lengths of Kraft paper, then cut each of these into strips 1½ inches wide by the length of the roll.  If you want, you can cut these in half to make them easier to glue together later. 

When you have several strips, roll each strip around the dowel lengthwise to form a long tube.  Glue down the overlapping edge in the middle, on the ends, and in between.  You should now have a paper tube being held together in a few places.  Squirt some of the glue underneath the portions of the edges that haven't been glued, and press them down.  It's ok if some of the glue oozes out; it shouldn't hurt your fingers.  Now run a line of glue down the seam of where the paper is glued to itself, and smear it around with the metal nozzle of the gun.  This helps insure an air tight seal so the gases won't leak out.  Let it all dry for about 10 seconds, then remove the dowel and proceed to making the next tube.