USS. Build the CONSTITUTION. The world s oldest commissioned naval vessel afloat

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1 USS CONSTITUTION Build the The world s oldest commissioned naval vessel afloat 05

Build the USS STAGE CONSTITUTION Contents PAGE 39 Bow frames 87 40 Stern frames 89 4

strips and a ladder 95 44 Wooden strips, a cannon and blocks 97 45 Wooden strips, a cannon

and pins 03 48 Wooden strips and grating strips 05 49 Wooden strips, a ladder and pins 07

Published in the UK by De Agostini UK Ltd, Battersea Studios, 8 Silverthorne Road, London

Calhoun Street, Woodstock, IL 60098 All rights reserved 07 Warning: Not suitable for

2 Build the USS STAGE CONSTITUTION Contents PAGE 39 Bow frames Stern frames 89 4 Grating strips, wooden strips and a ladder 9 4 Stern frames Grating strips, wooden strips and a ladder Wooden strips, a cannon and blocks Wooden strips, a cannon and a chain Wooden strips and grating strips 0 47 Wooden strips, a ladder, a cannon and pins Wooden strips and grating strips Wooden strips, a ladder and pins 07 Editorial and design by Continuo Creative, 39-4 North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios, 8 Silverthorne Road, London SW8 3HE. Published in the USA by De Agostini Publishing USA, Inc., E. Calhoun Street, Woodstock, IL All rights reserved 07 Warning: Not suitable for children under the age of 4. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown.

STAGE: 39 Bow frames 39C Sand the edges of

until they are flush with the surface of

E 39B Use a half-round file to remove the

3 STAGE: 39 Bow frames 39C Sand the edges of frame to ensure the forward ends of the strips are flush with it. C. Bow frames 39D Take the bow frames fret and mark it with the numbers shown. D 39A Smooth over the nails with A a file until they are flush with the surface of the strips. E 39B Use a half-round file to remove the heads of the nails at the stern and bow. B 39E Cut the frames out of the fret and smooth them with sandpaper. 87

39F Apply glue to one side of bow frame.

keel. 39H When bow frame is in H position, apply glue to frame and

4 39F Apply glue to one side of bow frame. F I G Place the bow frame up against the false keel and frame, as shown. 39I Repeat this process to fit bow frames 3, 4 and 5 to the bow frames and the false keel. G 39J Place the last three bow frames to the others and the false keel. 39H When bow frame is in H position, apply glue to frame and place it up against the false keel and bow frame. J K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 88

STAGE: 40 Stern frames 40C Place the bow frame up

Stern frames 40D Fit bow frames to 5 in order at

D A 40A Retrieve the bow frames 5 from Stage 38.

3 4 E 6 40B Take bow frame and apply glue to the

5 STAGE: 40 Stern frames 40C Place the bow frame up against the false keel and frame. C. Stern frames 40D Fit bow frames to 5 in order at the bow, up against the false keel. D A 40A Retrieve the bow frames 5 from Stage 38. Label the frames as shown here. 3 4 E 6 40B Take bow frame and apply glue to the side of it that will be in contact with hull frame. B E Now place bow frames 6, 7 and 8 at the bow.

40F Start shaping the bow frames with a sanding block to

F 40I Smooth the bow frames on the other side of the hull.

false keel, but be careful not to alter the shape of it.

and you can pass a wooden strip over them without

6 40F Start shaping the bow frames with a sanding block to start blending the frames together. F 40I Smooth the bow frames on the other side of the hull. I 40G When the frames are smoother, continue shaping them with a file. G 40J Make sure that the bow frames are flush with the false keel, but be careful not to alter the shape of it. 40H Continue sanding until the H bow frames are smooth and you can pass a wooden strip over them without obstruction. J 40K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 90

STAGE: 4 Grating strips, wooden strips and a ladder 4C Glue

ladder sides. C. Grating strips. x 3 x 300mm walnut strip 3.

x 4 x 00mm ramin strips 3 4D Stain the ladder in the same

D 5 4 4A Prepare the ladder sides, A 5 and cut one of the x

E 4 B 4B Glue a 6mm strip into the end slots of one of the

7 STAGE: 4 Grating strips, wooden strips and a ladder 4C Glue the remaining 6mm strips into the remaining slots in the ladder sides. C. Grating strips. x 3 x 300mm walnut strip 3. x x 300mm ramin strip 4. Ladder sides 5. x 4 x 00mm ramin strips 3 4D Stain the ladder in the same way as the others. D 5 4 4A Prepare the ladder sides, A 5 and cut one of the x 4mm ramin strips into six 6mm lengths. E 4 B 4B Glue a 6mm strip into the end slots of one of the ladder sides, then glue the other side onto the free ends, as shown. 4E When the ladder is complete, glue it into the opening in the grating frame. 9

4F Cut a 70mm length of the x 4mm ramin strip.

of grating from the piece assembled in Stage 35.

I 6mm 4H Glue the two 4 x 7 sections H 90 of grating to either

J 90 4J Glue the strips up against the gratings and the central

8 4F Cut a 70mm length of the x 4mm ramin strip. F 4I Cut two 6mm lengths of 70mm 4G Remove two 4 x 7 sections of grating from the piece assembled in Stage 35. Smooth the sides with sandpaper. G x 4mm ramin strip. I 6mm 4H Glue the two 4 x 7 sections H 90 of grating to either side of the 70mm strip of ramin, as shown. J 90 4J Glue the strips up against the gratings and the central strip. K 4K This stage is now complete. Store any materials that you haven t used, because they will be needed in future stages. 9

STAGE: 4 Stern frames 4C Now smooth the top

C. Stern frames 4D Place a x 5mm ramin strip

to fit. Cut the strip and glue into place.

D 4A Smooth the stern ends A of the walls, so that

indicated by the dotted line, on both sides of the

9 STAGE: 4 Stern frames 4C Now smooth the top reinforcement to match the angle of the walls above. C. Stern frames 4D Place a x 5mm ramin strip underneath the top reinforcement, as shown, and bend to fit. Cut the strip and glue into place. Then cut another to fit up against the first. D 4A Smooth the stern ends A of the walls, so that the angle joins up with the stern reinforcements, as indicated by the dotted line, on both sides of the hull. E 4B Here you can see how the walls should look when shaped. B 4E When the two strips have dried in position, cut any excess so the bottom edge is flush with the bottom of the reinforcements. 93

4F Smooth the strips and the reinforcements so that the angle is as

F 4I Then glue frames 4, 5 and 6 up against the false keel and the

I 4 6 5 G 4G Identfiy and label the stern frames as shown in the

Then remove the pieces from the fret, and smooth the edges with

4J Retrieve the stern frames from Stage 40, and repeat steps G to I

10 4F Smooth the strips and the reinforcements so that the angle is as shown in the inset. F 4I Then glue frames 4, 5 and 6 up against the false keel and the frames. I G 4G Identfiy and label the stern frames as shown in the photo. Then remove the pieces from the fret, and smooth the edges with sandpaper. 4J Retrieve the stern frames from Stage 40, and repeat steps G to I with them on the other side of the hull. 4H Glue stern frames, and 3 to the starboard side of the false keel at the stern, as shown, in the same way as the bow frames. H J 3 4K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 94

STAGE: 43 Grating strips, wooden strips and a ladder 43C

and cut one of the x 4mm ramin strips into six 6mm lengths.

11 STAGE: 43 Grating strips, wooden strips and a ladder 43C Glue the remaining 6mm strips into the remaining slots in the ladder sides. Stain the ladder in the same way as the others. C. Grating strips. Ladder sides 3. x 4 x 00mm ramin strips D 3 43A Prepare the ladder A sides and cut one of the x 4mm ramin strips into six 6mm lengths. 43D Glue the ladder into the remaining opening in the grating frame. 3 E B 43B Glue a 6mm strip into the end slots of one of the ladder sides, then glue the other side onto the free ends, as shown. 43E Assemble the grating strips, and fix them together with glue. 95

43F Remove four 4 x 7 grating pieces from the larger grating.

F 43G Glue two of the 4 x 7 grating pieces up against the strips of the

G H I 43I Glue the strips from the previous step up against the grating

43J Place the other two grating pieces up against the strips.

12 43F Remove four 4 x 7 grating pieces from the larger grating. Smooth the sides of the pieces. F 43G Glue two of the 4 x 7 grating pieces up against the strips of the assembly from Stage 4, as shown. G H I 43I Glue the strips from the previous step up against the grating pieces, as shown. 43J Place the other two grating pieces up against the strips. Then cut two more 6mm lengths of x 4mm ramin strip and glue them to the grating. J 6mm 43H Cut two 6mm lengths of x 4mm ramin strip. 43K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 96

STAGE: 44 Wooden strips, a cannon and blocks.

the curvature of the strips froward of them. C 5.

Blocks 7 44D Contiue shaping the stern frames until they

5 D 6 3 4 44A Sand the stern frames A until they are

13 STAGE: 44 Wooden strips, a cannon and blocks. x 5 x 300mm ramin strips. x x 300mm ramin strips 3. Cannon 4. Cannon wedge 44C Smooth the sides of the frames to match the curvature of the strips froward of them. C 5. Carriage base 6. Carriage 7. Blocks 7 44D Contiue shaping the stern frames until they align with the lines of the hull. 5 D A Sand the stern frames A until they are flush with the false keel. E 44B Begin shaping the rest of the stern frames with a halfround file. B 44E Repeat the process on the other side of the hull to shape the stern frames. 97

44F Once you have shaped the stern frames, smooth over the hull with sandpaper.

specifically smoothing the joins between them and the strips.

14 44F Once you have shaped the stern frames, smooth over the hull with sandpaper. 44I Ensure that there is at least a 5mm gap between the strips on either side of the hull, where the false keel is. F I 5mm 44G Use glue to secure any strips that are not held in position, so that they are all flat. G 44J Use a fine sandpaper to smooth along the walls on either side of the hull, specifically smoothing the joins between them and the strips. H 44H Make sure that all of the frames at the stern are flush with the frames and the false keel. J 44K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 98

STAGE: 45 Wooden strips, a cannon and a chain 45C Make sure the strip

x 5 x 300mm ramin strips. x x 300mm ramin strips 3. Cannon 4.

Chain 7 45D Prepare another x 5mm ramin strip and glue it aft of the

D 5 3 6 4 45A Take a x 5mm ramin A strip and sand smooth.

E 45B Fit the strip to the inside of the port wall, up against the

15 STAGE: 45 Wooden strips, a cannon and a chain 45C Make sure the strip is in the position shown below, then clamp into place. C. x 5 x 300mm ramin strips. x x 300mm ramin strips 3. Cannon 4. Cannon wedge 5. Carriage base 6. Carriage 7. Chain 7 45D Prepare another x 5mm ramin strip and glue it aft of the first strip. Clamp in place until dry. D A Take a x 5mm ramin A strip and sand smooth. Apply a little glue to one side of the strip. E 45B Fit the strip to the inside of the port wall, up against the deck, as shown. B 45E Prepare and fit a third strip to the wall to complete the row. Clamp in place and leave to dry. Cut the aft end of the third strip flush with the end of the wall. 99

45F When you have completed the first row, start another by placing a x

F 45G Continue fitting x 5mm ramin strips to the inside of the port wall

G H 45H When the glue has completely dried, remove the parts of the

I 45I Smooth the cuts with a file until the strips are flush with the

16 45F When you have completed the first row, start another by placing a x 5mm ramin strip above the first. F 45G Continue fitting x 5mm ramin strips to the inside of the port wall until it is covered. G H 45H When the glue has completely dried, remove the parts of the strips obstructing the gun ports. I 45I Smooth the cuts with a file until the strips are flush with the openings. 45J Also cut away strips covering the rectangular opening amidships. J 45K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 00

STAGE: 46 Wooden strips and grating strips 46C

x 5 x 300mm ramin strips. Grating strips 3.

x x 300mm ramin strip 3 4 46D Assemble the

D A 46A Glue three rows of x 5mm ramin strips

same way as the port wall in the previous stage.

17 STAGE: 46 Wooden strips and grating strips 46C Smooth the tops of the walls with sandpaper. C. x 5 x 300mm ramin strips. Grating strips 3. x 3 x 300mm walnut strip 4. x x 300mm ramin strip D Assemble the grating strips, and fix them together with glue. D A 46A Glue three rows of x 5mm ramin strips to the inside of the starboard wall, in the same way as the port wall in the previous stage. E 46B When the strips have dried, reopen all the openings in the walls. B 46E Remove four 4 x 7 sections of the grating piece just assembled. Smooth the pieces with sandpaper. 0

46F Retrieve the grating assembly (Stage 43) and glue two of the new 4 x 7 sections

46I Assemble the grating strips from Stage 4 F and secure them with glue.

I 46G Prepare and glue two 6mm lengths of x 4mm strip up against the grating pieces

46H Place the other two H grating pieces up against the strips, then place two more

18 46F Retrieve the grating assembly (Stage 43) and glue two of the new 4 x 7 sections up against the strips, as shown. 46I Assemble the grating strips from Stage 4 F and secure them with glue. Remove four 4 x 7 sections of the grating piece and smooth them with sandpaper. I 46G Prepare and glue two 6mm lengths of x 4mm strip up against the grating pieces and the central strip. G 46J Repeat steps F to H with the new grating pieces. 46H Place the other two H grating pieces up against the strips, then place two more strips up against them. J 46K This stage is now K complete. Store any materials that you haven t used, because they will be needed in future stages. 0

STAGE: 47 Wooden strips, a ladder, a cannon and pins 47C Make sure that no

If they are, remove the excess putty from them. C. 0.

Cannon 5. Cannon wedge 6. Carriage base 7. Carriage 8.

5mm. You may need to remove more putty to achieve this.

the hull with sandpaper to remove the excess.

5mm 5 the second set of hull strips, you should eliminate any

19 STAGE: 47 Wooden strips, a ladder, a cannon and pins 47C Make sure that no gun ports are blocked by any putty. If they are, remove the excess putty from them. C. 0.6 x 5 x 50mm sapele strips. Ladder sides 3. x 4 x 00mm ramin strips 4. Cannon 5. Cannon wedge 6. Carriage base 7. Carriage 8. Pins D The false keel at the bow and stern should have a thickness of 5mm. You may need to remove more putty to achieve this. D A Before you start to fit A 47B When the putty has dried, smooth the hull with sandpaper to remove the excess. Repeat the process if necessary. 5mm 5 the second set of hull strips, you should eliminate any irregularities in the surface of the hull. To do this, spread modelling putty over all of the hull with a spatula. E B 47E Once the surface of the hull is uniform, you can start placing the next layer of hull strips. Spread some glue thinly along a row of strips. 03

47F Take one of the sapele strips, and place it along the join between the wall and

F 47G Cut away the excess strip overlapping the false keel at the bow.

You may need to press the strips flat against the hull using a smooth handle, like

47J When dry, cut away the excess of the strip, extending past the stern.

20 47F Take one of the sapele strips, and place it along the join between the wall and the top strip, as shown. F 47G Cut away the excess strip overlapping the false keel at the bow. G I 47I Place a third strip along the join to complete the row. You may need to press the strips flat against the hull using a smooth handle, like the one shown here. 47J When dry, cut away the excess of the strip, extending past the stern. Repeat steps E to J on the other side of the hull. J H 47H Place a second sapele strip along the join, aft of the first. 47K This stage is now complete. K Store any materials that you haven t used, because they will be needed in future stages. 04

STAGE:48 Wooden strips and grating strips 48C

cut away the parts blocking the gun ports.

the previous stage, in the postition shown here.

21 STAGE:48 Wooden strips and grating strips 48C Continue the row aft with three more strips. C. 0.6 x 5 x 50mm sapele strips. Grating strips 48D When the strips have dried, cut away the parts blocking the gun ports. D A 48A Place a sapele strip above the row from the previous stage, in the postition shown here. E 48B When the strip has dried, trim the excess from the bow. B 48E Once you have removed the excess, glue another row of sapele strips above the last, then another row above that. 05

48H Make sure that the F 48F Cut away the

strips are flush with the stern, as shown.

48I Repeat the same process I G H (Steps A to

48J Trim away any strip ends J covering the

22 48H Make sure that the F 48F Cut away the strips covering the gun ports. strips are flush with the stern, as shown. 48G Place another two rows above the others. 48I Repeat the same process I G H (Steps A to H) on the starboard side of the ship. 48J Trim away any strip ends J covering the keel at the bow, ensuring there is a gap of 5mm. K 48K This stage is now complete. Store any materials that you haven t used, because they will be needed in future stages. 06

STAGE: 49 Wooden strips, a ladder and pins 49C Retrieve the

of grating to the central strip, as shown. C. 0.

x 4 x 00mm ramin strips 4. x 3 x 300mm walnut strip 5.

Pins 5 4 3 49D Cut away the excess of the central strip at the

D 6 A 49A Assemble the grating strips from the previous stage.

23 STAGE: 49 Wooden strips, a ladder and pins 49C Retrieve the grating assembly from Stage 46, and glue the two 3 x 7 sections of grating to the central strip, as shown. C. 0.6 x 5 x 50mm sapele strips. Ladder sides 3. x 4 x 00mm ramin strips 4. x 3 x 300mm walnut strip 5. x x 300mm ramin strip 6. Pins D Cut away the excess of the central strip at the end (arrowed). Smooth the sides with a sanding block. D 6 A 49A Assemble the grating strips from the previous stage. E B 49B Cut two 3 x 7 sections from the assembled grating and smooth the sides. 49E Create a frame around the grating assembly with x 3mm walnut strips. 07

49F Frame the walnut strips with x mm ramin strips.

H 49H Smooth the grating assembly, then stain and paint with a clear sealant.

49J Glue the grating assembly over the large opening in the centre of the deck, with

24 49F Frame the walnut strips with x mm ramin strips. F 49G Frame the insides of the G two openings with x 3mm walnut strips, as shown. H 49H Smooth the grating assembly, then stain and paint with a clear sealant. I 49I Cut away the beam in the large opening amidships. 49J Glue the grating assembly over the large opening in the centre of the deck, with the openings towards the bow. J K 49K This stage is now complete. Store any materials that you haven t used, because they will be needed in future stages. 08

USS. Build the CONSTITUTION. The world s oldest commissioned naval vessel afloat

USS. Build the CONSTITUTION. The world s oldest commissioned naval vessel afloat USS CONSTITUTION Build the The world s oldest commissioned naval vessel afloat 04 Build the USS STAGE CONSTITUTION Contents PAGE Wooden strips and a ladder 63 9 Wooden strips and nails 6 30 Wooden strips