Pack 8

Building the U.S.S. Constitution's small boats

Use a pencil to transfer the numbers from the IP sheets to the wooden boards.

Cut the ribs that join the pieces to the boards, so that they can be removed without damaging them.

Place the parts on a flat surface and sand them with a fine-grit sponge.

Watch our video for extra guidance.

Glue part 8.2 to part 8.1.

Glue part 8.3 to part 8.1.

Complete the structure of boat A with parts 8.4 to 8.12.

Build boat B with parts 8.13 to 8.23.

Build boat C with parts 8.24 to 8.36.

Build boat D with parts 8.37 to 8.48.

Build boat E with parts 8.49 to 8.59.

Glue parts 8.60 to boat A as shown. You may want to apply walnut stain to slightly darken the structures.

Glue the structure of boat A to part 8.61.

Use a file or sandblock to gently and progressively sand the structures of the five boats until they are smooth.

Sand the stern area of the boats in the same way.

Use a slightly wider sandblock for the central part of the boats.

Take boat A. Test-fit an 8.71 batten (1 x 30 x 150 mm lime wood) to check the sanding, and correct if necessary. Then, glue the batten precisely along the marks on the boat frames.

Glue another 8.71 batten on the other side of the boat to achieve a symmetrical finish.

Continue gluing battens, but this time starting from the middle of the boat.

Continue gluing battens until the gaps are closed.

Cut along the notches on the frames to separate the boats from their supports.

Smooth the top of the boats with a file.

Take boat A. Cut parts 8.72 (2 x 2 mm mahogany) to match the lengths on boat A as shown, then glue them in place.

File part 8.73 and adjust the frames to achieve a good fit.

Apply varnish to all the parts you have added to the boats.

Cut to length parts 8.79 to 8.83 (2 x 2 mm mahogany).

Glue together parts 8.88 and 8.83.

Use a sanding sponge to smooth part 8.89.

Take boat B. Apply super glue to the rim of the boat as shown, then centre and fit part 8.89.

Cut parts 8.94 (1 x 3 x 37 mm lime wood) and 8.95 (1 x 3 x 10 mm lime wood) to size (see table below), then sand their edges with a sanding sponge.

Fit and glue parts 8.112 and 8.113 (ø1 x 16 mm) to boat A.

Sand the rudders 8.114 to 8.118. Drill three ø0.50 mm holes in each rudder. Insert and glue parts 8.119 to each rudder. The third hole is for the tiller - see steps 4 and 5 for guidance.

Cut part 8.120 (ø0.50 x 32 mm) to make the tiller and glue into place. Drill two ø0.50 mm holes in boat A, then glue rudder 8.115 in place. After the glue has dried, shape the tiller.

Glue parts 8.121 to 8.123 together.

Glue part 8.121 as shown. Repeat this process to make a second assembly.

Sand and varnish the two assemblies.

Cut to size parts 8.124 (ø1 x 12 mm) and 8.125 (ø1 x 5 mm). Glue parts 8.124 and 8.125 to part 8.121 on the two assemblies as shown.

Glue parts 8.126 to the assemblies.

Paint part 8.127 black, then drybrush with red paint.

Cut to length part 8.128 (ø1.5 x 16 mm).

Smooth the ends of part 8.128 using a file.

Paint parts 8.129 and 8.130 black, then drybrush with red paint.

Fit parts 8.128 to 8.131 together.

Fit parts 8.129 and 8.130. Apply glue to part 8.130 to hold it in place.

Apply glue to the other side of the assembly then cut part 8.128 flush.

Glue parts 8.132 (from sheet 2001-23, supplied with pack 4) to each end of part 8.128.

Glue parts 8.134 (2 x 2 x 15 mm lime wood) and 8.135 (2 x 2 x 22 mm lime wood) to part 8.133. Varnish the assembly after the glue has dried.

Glue the assembly to the part you built in pack 6, stage 26.

Insert and glue part 8.127 (step 6).

Sand the back of part 8.136 (supplied with pack 4) to roughen it.

Place part 8.136 on the transom (stage 32), centring it with the windows. Use a pencil to trace the outline of part 8.136 onto the transom.

Apply contact adhesive to the marked area of the transom and to the back of part 8.136.

When the glue no longer sticky, press part 8.136 firmly against the transom so that it adheres properly.

Smooth the entire surface of the parts with fine-grit sponge sandpaper and remove any residue.

Use contact adhesive to glue part 8.137 in place.

Sand then glue part 8.138 (pack 4) centred on part 8.137.

The image shows the parts needed to decorate the transom. Decide whether you want to paint them or not before gluing the parts.

This image shows you how the parts will be placed on the transom, but do not glue them yet.

Paint the recesses of part 8.142 with black paint. Use a fine paintbrush or toothpick.

Take a 2 x 2 mm strip of lime wood and use a moulding scriber tool to create the shape shown in the image.

Cut to size part 8.146 (2 x 2 x 160 mm) from the shaped strip, then glue it against the brass part. Glue the second piece leaving a 4 mm gap as shown.

Paint part 8.147 (pack 4) black. When the paint is dry, use a fine sanding sponge to remove the paint from the lettering, keeping it in a flat position. This technique will give you well-defined lettering.

Paint the parts shown in the picture in black. These parts will form the stern gallery.

Clamp the transom to the hull. Fit the painted parts in place, then mark their position.

Cut and remove any planking that obstructs the painted parts.

Cut the ends of the shaped strips at an angle, then add smaller pieces to extend the strips around the side.

Paint the transom black.

Fit and glue parts 8.153 to 8.155.

Proceed in the same way to fit and glue the parts on the other side of the hull.

Paint the parts black.

Paint the back of the parts black.