Pack 03
BUILD INSTRUCTIONS
Instructions for building your Cutty Sark model ship
Your model of the Cutty Sark 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 frames.
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
| Material | Quantity | |
| Wooden Boards | ||
| 2002-8, 2002-9, 2002-10, 2002-11 | Wood | 4 |
| Wooden Strips | ||
| 5 x 5 x 400 mm | Oak | 9 |
| 3 x 3 x 400 mm | Lime wood | 6 |
| 2 x 3 x 600 mm | Lime wood | 15 |
| Wooden Rods | ||
| ø10 mm x 450 mm | Mahogany | 1 |
| Mast fittings | ||
| Foremast and mainmast collars (10 x 14 mm) (4.40) | 4 | |
| Mizzen mast collars (9 x 13 mm) (4.41) | 2 | |
| Templates | ||
| Assembly templates PL-05, PL-06 and PL07 | 3 |
Useful tools for building this model: 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, moulding scriber tool
PACK 03 - PARTS IDENTIFICATION
PARTS REFERENCE
PART NO. | REFERENCE | PART NO. | REFERENCE | PART NO. | REFERENCE |
| 3.1 | 2002-8 | 3.10 | 2002-9 | 3.19 | 2002-11 |
| 3.2 | 2002-8 | 3.11 | 2002-9 | 3.20 | 2002-11 |
| 3.3 | 2002-8 | 3.12 | 2002-9 | 3.21 | 2002-11 |
| 3.4 | 2002-8 | 3.13 | 2002-10 | 3.22 | 2002-11 |
| 3.5 | 2002-8 | 3.14 | 2002-10 | 3.23 | 2002-11 |
| 3.6 | 2002-8 | 3.15 | 2002-10 | 3.24 | 2002-11 |
| 3.7 | 2002-9 | 3.16 | 2002-10 | 3.25 | 2002-11 |
| 3.8 | 2002-9 | 3.17 | 2002-10 | 3.26 | 2002-8 / 2002-11 |
| 3.9 | 2002-9 | 3.18 | 2002-10 | 3.27 | 2002-3 (pack 1) |
For extra support and guidance, John Builds Iconic Military Models demonstrates his build of the Cutty Sark on his YouTube channel, sharing 30+ years of wooden ship-building experience. More recommended experts can be found in our Expert Directory and on our Forum.
Step 1
Write the numbers from the IP sheets onto the corresponding parts. Cut out the parts with a craft knife.
Only remove the parts you are working on in each step.
Step 2
Place parts 3.1 and 3.2 on the frame 21 outline on template PL-04 to check the fit.
Step 3
Apply glue to the parts then use pieces of masking tape to immobilise the parts on the template until the glue dries.
Step 4
Once the glue has dried, sand the frames with a fine-grit sanding sponge to remove any glue or paper residue. Write number 21 in pencil on the frame.
Step 5
Repeat this procedure to build frames 22–33, using templates PL-05 , PL-06 and PL-07 as guides. Write the frame numbers (22–33) in pencil on each frame.
Step 6
Test-fit frame 21 into the slots in the false keel and the building board.
Step 7
Remove the frame. File the slot if necessary.
Step 8
Apply glue to the slot, as shown.
Step 9
Insert and glue frame 21 into the slots in the false keel and the building board. Check that the frame is square to the building board using a set square.
Step 10
Repeat the same procedure to glue frames 22 to 33.
Step 1
File part 3.27 (from Pack 1, ref. 2002-3) so that it fits between frames 22 and 23.
Step 2
Glue part 3.27 centred between frames 22 and 23.
Step 3
Sand a 5 x 5 mm oak strip with fine-grit sandpaper or a sanding sponge. Then cut parts 3.28 to 3.33 to the lengths shown below.
| 3.28 | 5 x 5 x 131 mm |
| 3.29 | 5 x 5 x 131 mm |
| 3.30 | 5 x 5 x 130 mm |
| 3.31 | 5 x 5 x 130 mm |
| 3.32 | 5 x 5 x 129 mm |
| 3.33 | 5 x 5 x 127 mm |
Step 4
Insert and glue parts 3.28 to 3.33 between the lower recesses, as shown.
Step 5
Cut parts 3.34 to 3.39 from a 5 x 5 mm oak strip to the lengths shown below.
| 3.34 | 5 x 5 x 125 mm |
| 3.35 | 5 x 5 x 123 mm |
| 3.36 | 5 x 5 x 120 mm |
| 3.37 | 5 x 5 x 117 mm |
| 3.38 | 5 x 5 x 114 mm |
| 3.39 | 5 x 5 x 110 mm |
Step 6
Insert and glue the oak strips between the lower recesses, as shown.
Step 7
Sand a 3 x 3 mm lime wood strip with fine-grit sandpaper or a sanding sponge.
Cut parts 3.40 (3 x 3 x 15 mm) to length.
Step 8
Insert parts 1.28 between the frames to keep them parallel. Do not glue.
Glue parts 3.40 in line with the previous parts. Use a ruler to keep the strips aligned, as indicated by the red line.
Step 9
Continue to glue parts 3.40 up to frame 31.
Step 10
This image shows the assembly at the end of this stage. It is important to keep the structure on the building board at all times.
