Pack 11

BUILD INSTRUCTIONS

      If you'd prefer to download a PDF version of these instructions, choose to save as PDF from the print dialog.

      Instructions for building your USS Constitution model ship

      Your model of the USS Constitution is divided into 12 packs.

      You will need to follow the step-by-step assembly photos, the plans and the explanatory texts below.

      Please save the leftover materials from each pack for use when instructed to do so at a later stage of the assembly instructions.

      The IP sheets displayed below are drawings of laser-cut parts and photo-etched brass parts and will serve as a guide for identification of some parts.

      Use the PARTS REFERENCE table to help locate the parts.

      The PL-00 templates (printed at 1/1 scale) included in each pack will serve as a guide for building the model.

      Please check the list below to ensure you have all the tools required for building your wooden ship.

      When removing a part, cut the ribs that join the part to the wooden plate with a cutter.

      Remove the parts carefully so as not to break them.

      Keep and store the parts in their frames. Only remove the parts you are working on in each step.

      Extra support can be found on our forum or from the Expert Directory page of our website.

      PARTS LIST

      MaterialQuantity
      Wooden Rods
      ø3 x 400 mmMahogany6
      ø4 x 400 mmMahogany7
      ø5 x 400 mmMahogany6
      ø6 x 400 mmMahogany7
      ø8 x 400 mmMahogany6
      Wooden Strips
      1 x 5 x 600 mmLime wood5
      3 x 3 x 400 mmLime wood3
      2 x 5 x 600 mmLime wood5
      2 x 2 x 600 mmMahogany5
      2 x 3 x 600 mmLime wood1
      2 x 2 x 600 mmLime wood1
      1 x 3 x 600 mmLime wood10
      Thread
      ø0.15 x 25,000 mm (natural)Cotton18
      ø0.15 x 25,000 mm (brown)Cotton4
      ø0.5 x 15,000 mm (brown)Cotton10
      ø0.8 x 10,000 mm (brown)Cotton8
      Other Parts
      Masts and rigging drawing set (22 A3 sheets)1

      Tools you will need: cutting mat, pencil, cutting knife, fine-grit sandpaper or sponge sandpaper, file, white wood glue, super glue (cyanoacrylate glue), masking tape, set square, hacksaw, sanding block, 30 cm steel ruler, clamps, drill, moulding scriber tool

      PARTS REFERENCE

      PART NO.
      IP-SHEET LOCATION
      PART NO.
      IP-SHEET LOCATION
      PART NO.
      IP-SHEET LOCATION
      MT42001-24MT742001-11MT1302001-31
      MT52001-31MT802001-11MT1442001-24
      MT182001-11MT882001-31MT1472001-31
      MT302001-31MT892001-31MT1482001-31
      MT312001-31MT1002001-24MT1492001-31
      MT452001-24MT1032001-31MT1502001-31
      MT482001-31MT1042001-31MT1512001-24
      MT502001-31MT1052001-31MT1692001-11
      MT512001-31MT1062001-31MT1742001-11
      MT522001-24MT1072001-24  
      MT642001-38MT1292001-31  

      Stage 61

      Step 1

      Cut 10.26 threads (ø0.5 x 125 mm brown) to length, attach them to the cannons and carronade, and glue them to the deck as shown.

      The cannons and carronades should also be glued to the deck.

      a

      Step 2

      Building the Bowsprit

      Refer to the 1/1 scale mast and rigging drawings for this pack.

      Lay part MT1 (ø10 x 230 mm) on the bowsprit drawing and mark the required length on the rod.

      Watch our video for extra guidance.

      a

      Step 3

      Taper part MT1 using a sanding block to achieve the profile shown on the drawing.

      a

      Step 4

      Cut part MT1 to the marked length.

      a

      Step 5

      Reduce the diameter at the base of part MT1 using a file or cutter.

      a

      Step 6

      Place part MT1 on the drawing to check its length and profile.

      a

      Step 7

      Trim the upper end of part MT1 using the drawing as reference.

      a

      Step 8

      Smooth the end with a flat file.

      a

      Step 9

      Shape the end of part MT1 so that it fits into the square hole in part MT4, as shown on the drawing.

      a

      Step 10

      Sand part MT1 with a fine-grit sanding sponge.

      a

      Step 11

      Assemble parts MT12 (ø3 x 78 mm mahogany), MT13 (3 x 3 x 5 mm lime wood) and MT16 (ø3 x 26 mm mahogany) and build the structure shown using the drawing.

      a

      Step 12

      Make part MT20 (ø5 × 240 mm mahogany) with tapered ends using the drawing.

      a

      Step 13

      Check that the bowsprit parts shown in the image have been prepared, using the drawing and the table below as a reference.

      MT1ø10 x 230 mm mahogany
      MT2ø6 x 193 mm mahogany
      MT3ø3 x 231 mm mahogany
      MT12ø3 x 78 mm mahogany
      MT16ø3 x 26 mm mahogany
      MT20ø5 x 240 mm mahogany
      a

      Stage 62

      Step 1

      Make parts MT8 (3 x 3 x 20 mm lime wood) and MT9 (2 x 5 x 26 mm lime wood). Cut out parts MT5 (Pack 07) and MT18 (Pack 02).

      a

      Step 2

      File the upper hole in part MT4 so that part MT2 can be inserted later.

      a

      Step 3

      Adjust the shape of part MT4 to match the drawing.

      a

      Step 4

      Insert parts MT1 and MT2 through part MT4.

      a

      Step 5

      Cut two parts MT15 (ø1 x 14 mm brass) to length, then use pliers to bend one of the parts as shown.

      a

      Step 6

      Cut to length parts MT10 (ø1 x 30 mm brass) and MT14 (ø1 x 16 mm brass), then use pliers to bend and shape the parts.

      a

      Step 7

      Glue the parts shown in the image to the assemblies.

      MT72 x 2 x 5 mm lime wood
      MT83 x 3 x 20 mm lime wood
      MT92 x 5 x 26 mm lime wood
      a

      Step 8

      Drill ø1.5 mm holes in the bowsprit, then fit parts MT14 and glue the two assemblies together.

      a

      Step 9

      Glue the parts shown in the image.

      a

      Step 10

      This image shows the alignment of the wooden parts from a different angle.

      a

      Step 11

      Varnish all the wooden parts on the assembly.

      a

      Stage 63

      Step 1

      Cut off the ends of the eyebolts (B) as shown.

      a

      Step 2

      You will need to use different threads to attach blocks D, E, F and G to the masts. Tie a knot around block D using thread C (ø0.15 mm), then apply glue to the knot.

      a
      b

      Step 3

      Repeat this process to tie thread around block E.

      a

      Step 4

      Cut brown thread to length and tie to deadeye F and block D.

      MT19ø0.5 x 100 mm brown thread
      MT21ø0.5 x 150 mm brown thread
      a

      Step 5

      Glue parts MT7 and drill holes in part MT20 as shown on the drawing.

      a

      Step 6

      Fit all parts B, D and MT21 shown in the image, referring to the drawing and Step 7 below.

      a

      Step 7

      Tie part MT23 (ø0.5 x 125 mm brown thread) as shown. Leave one end of part MT23 unsecured, so it can be attached to the mast at a later stage.

      a

      Step 8

      Tie all the single- and multi-sheave blocks in place, as shown in the drawings.

      a

      Step 9

      Continue to fit all the parts shown in the drawings to the bowsprit.

      MT6ø0.5 x 100 mm brown thread
      MT11ø0.5 x 75 mm brown thread
      MT19ø0.5 x 100 mm brown thread
      a

      Step 10

      Fit part MT17 (ø0.5 x 250 mm brown thread) to complete the bowsprit.

      a

      Stage 64

      Step 1

      Foremast

      Make the parts shown in the image using the drawings. Part MT24 was prepared in pack 3.

      MT24ø10 x 387 mm mahoganyMT67ø3 x 160 mm mahogany
      MT46ø8 x 227 mm mahoganyMT71ø6 x 243 mm mahogany
      MT54ø6 x 125 mm mahoganyMT78ø3 x 128 mm mahogany
      MT56ø3 x 242 mm mahoganyMT79ø5 x 182 mm mahogany
      MT59ø8 x 326 mm mahoganyMT82ø4 x 115 mm mahogany
      a

      Step 2

      Cut to length seven parts MT36 (2 x 5 x 73 mm lime wood) and eight parts MT37 (2 x 5 x 22 mm lime wood).

      a

      Step 3

      Glue the edges of the parts, then fit them together as shown.

      a
      b

      Step 4

      Once the glue has dried, sand the edges with a sanding block.

      a

      Step 5

      Glue the parts together to assemble the foremast top, as shown on the drawing.

      a

      Step 6

      Shape the mast top with a sanding block to match the profile on the drawing.

      a

      Step 7

      Smooth the mast top as shown.

      a

      Step 8

      Cut to length twenty parts MT38 (2 x 2 x 25 mm mahogany).

      a

      Step 9

      Glue parts MT38 to the mast top as shown on the drawing.

      a

      Step 10

      Cut off the excess.

      a

      Step 11

      Drill holes into the mast top as shown on the drawing.

      a

      Step 12

      Smooth the ends of the parts with a sanding block.

      a

      Stage 65

      Step 1

      Make a hole in the foremast top, then use a file to shape the hole as shown in the image.

      a

      Step 2

      Cut to length two parts MT39 (1 x 5 x 174 mm lime wood), then soak them in water.

      a

      Step 3

      Use a cylindrical object to shape one part MT39.

      a

      Step 4

      Fit and glue parts MT39 to the mast top.

      a
      b

      Step 5

      Cut to length five parts MT40 (ø1 x 14 mm brass).

      a

      Step 6

      Cut to length part MT41 (2 x 2 x 60 mm mahogany), then mark the position of the holes.

      a

      Step 7

      Drill holes (ø1 mm) into part MT41.

      a

      Step 8

      Fit and glue parts MT40 and MT41 to the mast top.

      a

      Step 9

      Drill holes (ø1 mm) in the mast top as shown on the drawing.

      a

      Step 10

      Cut to length two parts MT32 (3 x 3 x 67 mm lime wood), then shape using a file.

      a

      Step 11

      Drill holes (ø1 mm) in parts MT32 as shown on the drawing.

      a

      Step 12

      Glue parts MT31 together as shown.

      a

      Step 13

      Cut to length part MT33 (3 x 3 x 14 mm lime wood), then glue the parts together as shown on the drawing.

      a

      Step 14

      Cut parts MT34 (3 x 3 x 13 mm lime wood) and shape them as shown, then glue to the assembly.

      a

      Step 15

      Build the assembly shown in the image.

      a

      Stage 66

      Step 1

      Cut to length two parts MT25 (1 x 5 x 83 mm lime wood) and one part MT26 (1 x 5 x 198 mm lime wood), then shape the ends as shown.

      a

      Step 2

      Apply contact glue to one side of the parts.

      a

      Step 3

      Glue part MT26 to part MT24 (ø10 x 387 mm) as shown.

      a

      Step 4

      Glue parts MT25 as shown.

      a

      Step 5

      Fit the assembly (stage 65, step 15) to the mast as shown.

      a

      Step 6

      Glue parts MT30 in place.

      a

      Step 7

      Use a rod to shape part MT27 (2 x 35 mm brass).

      a

      Step 8

      Cut the shaped part with pliers as shown.

      a

      Step 9

      Fit parts MT27 to the assembly.

      a

      Step 10

      Fit and glue the mast top.

      a

      Step 11

      Glue the parts shown in the image.

      a

      Step 12

      Make and glue five parts MT47 (1 x 5 x 18 mm lime wood).

      a

      Stage 67

      Step 1

      File the holes of parts MT55 so that parts MT54 and MT56 can fit through (see step 3).

      a

      Step 2

      You can choose to paint the parts black if you prefer.

      a

      Step 3

      Fit the parts shown to continue building the mast.

      MT532 x 2 x 10 mm lime wood
      MT54ø6 x 125 mm mahogany (stage 64)
      MT56ø3 x 242 mm mahogany (stage 64)
      MT571 x 3 x 8 mm lime wood
      a

      Step 4

      Make the mainmast and mizzenmast following the same method.

      MT84ø10 x 420 mmMT125ø8 x 322 mm
      MT101ø8 x 255 mmMT145ø6 x 195 mm
      MT109ø6 x 131 mmMT153ø5 x 96 mm
      MT110ø3 x 243 mmMT154ø3 x 201 mm
      a

      Step 5

      Fit part MT58 (2 x 5 x 5 mm lime wood) to the top of the masts.

      a

      Step 6

      Cut and shape the brass wire to length, then glue to the masts as shown.

      MT42ø1 x 15 mm brass
      MT44ø1 x 39 mm brass
      a

      Stage 68

      Step 1

      Adding Fittings and Rigging to the Yards for the Foremast

      Fit parts MT60 (1 x 3 x 85 mm lime wood) to part MT59 as shown on the drawing.

      a

      Step 2

      Fit and glue parts MT43 (2 x 2 x 5 mm lime wood) and MT63.

      a

      Step 3

      Take part MT64 from pack 4. Use pliers to shape the parts as shown in the image.

      MT65ø0.5 x 15 mm
      MT66ø1 x 25 mm
      MT68ø0.5 x 100 mm
      a

      Step 4

      Fit the parts as shown.

      a

      Step 5

      Take parts MT61 (parrel cleats, pack 9) and paint them black. Fit parts MT61 to the assembly as shown.

      a

      Step 6

      This image shows all the finished foresail yards. Repeat the process to make all the yards following the drawings.

      MT67ø3 x 160 mm mahoganyMT78ø3 x 128 mm mahogany
      MT69ø0.8 x 225 mm brown threadMT79ø5 x 182 mm mahogany
      MT71ø6 x 243 mm mahoganyMT81ø0.5 x 175 mm brown thread
      MT70ø0.5 x 150 mm brown threadMT82ø4 x 115 mm mahogany
      MT75ø0.5 x 125 mm brown threadMT83ø0.5 x 150 mm brown thread
      MT77ø0.8 x 200 mm brown thread
      a

      Step 7

      The following table may be useful for referencing sizes of the different parts.

      Part NumberMeasurementsMaterialQuantity
      MT84ø10 x 420 mmMahogany1
      MT851 x 5 x 229 mmLime wood1
      MT861 x 5 x 92 mmLime wood2
      MT872 x 3 x 8 mmLime wood1
      MT88PrecutMahogany2
      MT89PrecutMahogany4
      MT903 x 3 x 75 mmLime wood2
      MT913 x 3 x 14 mmLime wood1
      MT923 x 3 x 13 mmLime wood2
      MT93ø0.8 x 150 mmBrown thread2
      MT942 x 5 x 83 mmLime wood8
      MT952 x 5 x 24 mmLime wood10
      MT962 x 2 x 30 mmMahogany20
      MT971 x 5 x 195 mmLime wood2
      MT98ø1 x 14 mmBrass5
      MT992 x 2 x 79 mmMahogany1
      MT100PrecutMahogany1
      MT101ø8 x 255 mmMahogany1
      MT1021 x 5 x 18 mmLime wood5
      MT103PrecutMahogany2
      MT104PrecutMahogany1
      MT105PrecutMahogany1
      MT106PrecutMahogany1
      MT107PrecutMahogany1
      MT1082 x 2 x 10 mmLime wood4
      MT109ø6 x 131 mmMahogany1
      MT110ø3 x 243 mmMahogany1
      MT1111 x 3 x 10 mmLime wood5
      MT112ø8 x 371 mmMahogany1
      MT1131 x 3 x 85 mmLime wood9
      MT114ø3 x 182 mmMahogany2
      MT115ø0.5 x 100 mmBrass8
      MT116ø0.8 x 225 mmBrown thread2
      MT117ø6 x 279 mmMahogany1
      MT1181 x 3 x 58 mmLime wood6
      MT119ø0.8 x 200 mmBrown thread2
      MT120ø3 x 146 mmMahogany2
      MT121ø5 x 188 mmMahogany1
      MT122ø0.5 x 175 mmBrown thread2
      MT123ø4 x 125 mmMahogany1
      MT124ø0.5 x 150 mmBrown thread2
      MT125ø8 x 322 mmMahogany1
      MT126PrecutMetal1
      MT1272 x 25 mmBrass6
      MT128ø0.8 x 100 mmBrown thread1
      MT129PrecutMahogany2
      MT130PrecutMahogany4
      MT1313 x 3 x 12 mmLime wood1
      MT1323 x 3 x 58 mmLime wood2
      MT1333 x 3 x 13 mmLime wood2
      MT134ø5 x 182 mmMahogany1
      MT135PrecutBrass10
      MT136ø0.8 x 150 mmBrown thread1
      MT1372 x 5 x 64 mmLime wood6
      MT1382 x 5 x 20 mmLime wood8
      MT1392 x 2 x 25 mmMahogany20
      MT1401 x 5 x 150 mmLime wood2
      MT141ø1 x 31 mmBrass8
      MT142ø1 x 14 mmBrass5
      MT1432 x 2 x 60 mmMahogany1
      MT144PrecutMahogany1
      MT145ø6 x 195 mmMahogany1
      MT1461 x 5 x 13 mmLime wood5
      MT147PrecutMahogany2
      MT148PrecutMahogany1
      MT149PrecutMahogany1
      MT150PrecutMahogany1
      MT151PrecutMahogany1
      MT152PrecutMetal2
      MT153ø5 x 96 mmMahogany1
      MT154ø3 x 201 mmMahogany1
      MT1551 x 3 x 15 mmLime wood5
      MT156ø6 x 298 mmMahogany1
      MT1571 x 3 x 58 mmLime wood6
      MT158ø0.5 x 100 mmBrass4
      MT159ø0.5 x 100 mmBrown thread1
      MT160ø0.8 x 200 mmBrown thread2
      MT161ø5 x 193 mmMahogany1
      MT162PrecutMahogany2
      MT163ø0.8 x 200 mmBrown thread2
      MT164ø4 x 127 mmMahogany1
      MT165ø0.5 x 175 mmBrown thread2
      MT166ø4 x 85 mmMahogany1
      MT167ø0.5 x 150 mmBrown thread2
      MT168ø4 x 211 mmMahogany1
      MT169PrecutMahogany2
      MT170ø0.8 x 80 mmBrown thread4
      MT171PrecutMetal1
      MT1722 x 2 x 4 mmLime wood8
      MT173ø4 x 157 mmMahogany1
      MT174PrecutMahogany2
      MT175ø0.5 x 100 mmBrown thread4
      MT176ø0.5 x 175 mmBrown thread1

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