Pack 01

Prepare parts 1.1–1.7 as follows. Write the numbers using a pencil on the corresponding parts, referring to the diagrams above.

Cut out the parts with a craft knife.

Only remove the parts you are working on in each step, and do so carefully to avoid breaking them.

Sand the parts with fine-grit sandpaper or sanding sponge.

Use a small file to remove any remnants of the connecting ribs from the parts.

Parts 1.1 to 1.7 form the false keel.

Place parts 1.8 and 1.9 on a flat surface, align them as shown, then glue the parts together.

Apply white glue to one side of part 1.10.

Important: Do not glue any of the parts in the following steps unless stated otherwise.

Fit parts 1.1 and 1.2 together, then insert them into the slots of the building board, as shown.

Fit parts 1.3 and 1.4 together, then insert them into the slots of the building board, as shown.

Join the two assemblies together in the slots, as shown.

Insert parts 1.11 and 1.12 into the slots to hold the false keel in position, as shown. Do not glue.

Insert the remaining parts 1.11 and 1.12 into the slots.

Apply white glue to one side of parts 1.5, as shown.

Glue one part 1.5 to each side of the joint between parts 1.1 and 1.2 ensuring that parts 1.5 are aligned. Take care not to get glue on part 1.11.

Hold the parts firmly together with a clamp or a similar tool while the glue dries. Keep the assembly immobilised on the building board at all times.

Glue parts 1.6 to the assembly, as shown.

Glue parts 1.7 to the assembly, as shown.

Prepare parts 1.13–1.22 as follows. Write the numbers using a pencil on the corresponding parts, referring to the diagrams above.

Cut out the parts with a craft knife.

Only remove the parts you are working on in each step, and do so carefully to avoid breaking them.

Sand the parts with fine-grit sandpaper or sanding sponge.

You can colour in the pale wood areas using a black marker.

Template PL-01 will serve as a guide for building the frames. Place parts 1.13 and 1.14 on the frame 3 outline to check the fit.

Expert Tip: you might find it helpful to lay a sheet of transparent plastic material over the template before gluing the frames. This will prevent the glue from sticking to the template.

Apply glue to the ends of parts 1.14 and glue the pieces together to build frame 3.

Use pieces of masking tape (painter's tape) to immobilise the parts on the template until the glue dries.

Follow the same procedure to build frames 4, 5 and 6.

Sand the frames with a fine-grit sanding sponge to remove any glue or paper residue.

You should now have six frames. Write the frame numbers (1–6) in pencil on each corresponding frame to identify them.

Take the false keel and prepare it for inserting the frames by filing the slots if needed.

Apply white glue to the fourth vertical slot of part 1.1, where frame 4 will make contact.

Insert frame 4 into the slots in the false keel and the building board. The frame should be glued to the false keel, but not to the building board.

Check that frame 4 is square to the building board using a set square.

Repeat the same procedure to glue and insert frames 5 and 6.

Insert and glue frames 1, 2 and 3. Keep the parts immobilised on the building board until the glue dries.

The assembly should now look like this with the first six frames in place.

Sand a 5 x 5 mm oak strip with fine-grit sandpaper or sanding sponge.

Measure a length of 71 mm for part 1.23 (5 x 5 x 71 mm).

Cut part 1.23 using a saw.

Sand both ends of the part using a sanding block or a flat file.

Apply glue to the ends of part 1.23.

Insert part 1.23 on the inside of frame 6, between its lower recesses.

Cut parts 1.24–1.27 to the required length from a 5 x 5 mm oak strip.

Test-fit the oak strips between the frames, then glue each strip in place.

Insert parts 1.28, without gluing, between the frames to keep them parallel.

Keep parts 1.28 in position for the next stage when working on the deck framework.

Measure the distance between the deck beams on the frames.

Sand a 3 x 3 mm oak strip with fine-grit sponge sandpaper.

Cut eight parts 1.29 to the length measured in step 1 (approx. 3 x 3 x 15 mm).

Sand or file the ends of parts 1.29.

Apply white glue, or super glue if preferred, to the ends of parts 1.29.

Glue two parts 1.29 level with the deck beams. Check the alignment with a ruler, then glue four more parts 1.29, as shown.

Glue the remaining parts 1.29, aligned with the previous ones.

Remove parts 1.28 once the glue has dried.

Sand the deck framework with fine-grit sandpaper or a sanding sponge.

Apply clear varnish to the deck framing now, as it will be difficult to reach later. It is not necessary to varnish the slots in the frames, the frame legs or the building board.