Pack 9

BUILD INSTRUCTIONS

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      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 Strips
      1 x 4 x 100 mmLime wood14
      Other Parts
      Wire ø1 x 100 mmBrass35
      Wire ø1.5 x 100 mmBrass5
      Wire ø0.5 x 100 mmBrass60
      Ring ø3 mmBrass125
      Set of ladder stringers7
      Large cleatBrass2
      Small cleatBrass12
      Pulley 4 mm150
      Block 4 mm75
      Boom bandBrass1
      Mast bandBrass2
      DeadeyeBrass6
      Window glassAcetate2

      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
      9.52001-229.242001-239.302001-23
      9.62001-229.252001-239.312001-23
      9.92001-229.262001-239.392001-29
      9.102001-229.272001-239.462001-32
      9.112001-229.282001-239.472001-32
      9.222001-239.292001-239.502001-33
      9.232001-239.302001-239.512001-32

      Stage 49

      Step 1

      Cut eight parts 9.1 (2 x 2 x 136 mm mahogany) to length and sand them.

      a

      Step 2

      Fit and glue parts 9.1 onto part 9.2 (capstan, pack 08) as shown.

      a

      Step 3

      Continue to fit and glue parts 9.1 to the assembly as shown.

      a

      Step 4

      Use a rounded file to shape parts 9.1.

      a

      Step 5

      Drill eight holes (ø1 mm) into part 9.2 as shown in the image (see step 8).

      a

      Step 6

      Apply varnish to the assembly.

      a

      Step 7

      Cut to length eight parts 9.3 (ø1 x 10 mm).

      a

      Step 8

      Insert and glue parts 9.3 as shown in the image.

      a

      Step 9

      Cut to length and glue parts 9.4 (2 x 5 x 17 mm lime wood) together as shown.

      a

      Step 10

      Glue part 9.2 centred on parts 9.4. Varnish parts 9.4, then set aside.

      a

      Step 11

      Glue parts 9.5 together.

      a

      Step 12

      Glue two more parts 9.5 to the assembly.

      a

      Step 13

      Glue the assembly centred on part 9.6.

      a

      Step 14

      Cut four parts 9.7 to size (4 x 4 x 20 mm mahogany) and drill a hole in each one as shown in the image.

      a

      Step 15

      Cut parts 9.8 (ø1 x 8 mm) to length and insert them.

      a

      Step 16

      Glue parts 9.9 and 9.10 together.

      a

      Step 17

      Glue parts 9.11 as shown to complete the assembly.

      a

      Step 18

      Apply varnish to the two assemblies shown in the image.

      a

      Stage 50

      Step 1

      Take one of the sheets of acetate then scratch one of its sides using sandpaper or similar.

      a

      Step 2

      Cut out parts 9.12, 9.13 and 9.14 (two of each part). These parts represent the window glass. Glue the parts inside the two assemblies as shown.

      9.12: 5 x 15 mm
      9.13: 8 x 14 mm
      9.14: 8 x 17 mm
      a

      Step 3

      This image shows the assemblies with the acetate glued in place.

      a

      Step 4

      Cut to length eighteen parts 9.15 (1 x 4 x 7 mm lime wood).

      a

      Step 5

      Fit and glue parts 9.15 into part 9.16 (ladder stringer).

      a

      Step 6

      Glue part 9.17 to complete the ladder. Repeat this process to build a second ladder.

      Build five wide ladders using parts 9.16, 9.17 and 9.18 (1 x 4 x 12 mm) in the same way. Once complete, varnish all the ladders.

      a

      Step 7

      Cut to length four parts 9.19 (1 x 5 x 12 mm), then glue the parts together in the form of a curve as shown.

      a

      Step 8

      Paint the curved parts black, then glue hinges 7.9 to the parts as shown, and fit the hinges in place using nails (A).

      a

      Step 9

      Drill and cut the openings shown in the image. You can position the transom in place to show where to drill (see Stage 51 Step 3 below).

      a

      Step 10

      Paint the outside of the hull black as shown.

      a

      Step 11

      Cut to size the parts 9.20 and 9.21 from acetate. Sand the parts then paint one side black.

      9.20: 17 x 17 mm
      9.21: 20 x 40 mm
      a

      Step 12

      Glue parts 9.20 to the windows at each end of the transom.

      a

      Stage 51

      Step 1

      Adjust and bend parts 9.22 to fit the ornaments as shown in the images below, then paint them black.

      a

      Step 2

      Glue part 9.21 on the inner side of the windows 9.22. Glue parts 8.148 (port gallery crown) and 8.150 (port gallery base) to part 9.22 as shown in the image.

      a

      Step 3

      Fit and glue the transom to the hull.

      a

      Step 4

      Adjust the gallery crown and gallery base as needed so that they fit the transom, then glue the gallery crown and gallery base to the side of the hull as shown.

      a

      Step 5

      Adjust the column parts 9.23 to 9.26 to fit, paint them white, then glue them in place as shown.

      a

      Step 6

      Repeat steps 1 – 5 to fit the windows to the opposite side of the hull. You can use portions of black painted battens to fill in gaps where needed.

      a

      Step 7

      Glue parts 9.27 on both sides of the hull stem.

      a

      Step 8

      Retrieve the rudder blade that you built in Pack 07. Fit the hinges 7.6 onto the shafts.

      a

      Step 9

      Adjust and secure the rudder blade to the hull using nails (A). You will need to shape and adjust the parts on the model. Then glue parts 9.28, 9.29, and 9.30 to ensure the continuity of the hinges, before fixing them with nails (A).

      a

      Step 10

      This image shows the hinges in the upper part of the assembly from another angle.

      a

      Step 11

      Glue parts 9.31 on both sides of the assembly as shown.

      a

      Step 12

      Fit nails (A) to both parts 9.31.

      a

      Step 13

      Make the necessary adjustments so that part 9.32 and part 9.33 (stern ornaments) can be fitted, one on each side of the hull.

      a

      Step 14

      Fit and glue the transom ornaments that were painted in Pack 08 to the transom.

      Make parts 9.34 to 9.36 and paint them white, then glue them to the transom.

      9.342 x 2 x 6 mm lime wood
      9.35ø1 x 114 mm brass
      9.36ø1 x 118 mm brass
      a

      Stage 52

      Step 1

      Assemble the two davits using parts 9.37 (6 x 6 x 32 mm African walnut) and 9.38 (2 x 24 mm brass), then drill ø0.75 mm holes to fit eyebolts (B) as shown.

      a

      Step 2

      Using the whole ship elevation drawing as a guide, drill and cut the holes for the davits.

      a

      Step 3

      Insert a davit, fit part 9.39, then glue in place. Cut to length part 9.40 (2 x 21 mm brass) and glue as shown in the image.

      a

      Step 4

      Proceed in the same way to attach the parts on the other side of the hull.

      a

      Step 5

      Using the deck plan, insert and fix the eyebolts (B), as shown.

      a

      Step 6

      Continue to fit the eyebolts (B) as shown.

      a

      Step 7

      Fit the eyebolts (B) in the mizzenmast area as shown.

      a

      Step 8

      Cut brass wire to the lengths shown below, then paint them white and glue to the hull as shown. Repeat this step on the other side of the hull.

      9.41: ø1 x 137 mm9.44: ø1 x 133 mm
      9.42: ø1 x 135 mm9.45: ø1.5 x 55 mm
      9.43: ø1 x 135 mm 
      a

      Step 9

      Fit and glue parts 9.46 and 9.47 on both sides of the hull.

      a

      Step 10

      This image shows the hull with the bow parts in place.

      a

      Stage 53

      Step 1

      Cut parts 9.46 at the laser marks.

      a

      Step 2

      Cut out the openings as shown in the image. Cut parts 9.48 (1 x 5 x 10 mm lime wood) and 9.49 (1 x 5 x 8 mm lime wood) to size, then glue them in place to line the edges of the openings.

      a

      Step 3

      Retrieve the wide ladders you built previously. Check their fit and adjust their height if needed, then glue them in place, referring to the deck plan.

      a

      Step 4

      Fit and glue the three remaining ladders in the aft area as shown on the deck plan.

      a

      Step 5

      Referring to the plan and the images below, fit and glue parts 9.50 and 9.51, then glue in place the davits 6.29 that you built in Pack 06.

      a

      Step 6

      Drill the holes to insert the eyebolts B. Attach the chain 9.52 (1 x 300 mm) to the eyebolts as shown in the picture.

      a

      Stage 54

      Step 1

      Retrieve the pin rails built in Pack 06 and fit them, referring to the deck plan. Then fit parts 9.7 onto the deck as shown.

      a

      Step 2

      Continue to fit the pin rails to the assembly as shown in the image.

      a

      Step 3

      This is how the ship looks once this pack has been completed.

      a

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